In oil and gas wells, openings may be created in a production liner for injecting fluid into a formation. In a “plug and perf” frac job, for example, the production liner is made up from standard lengths of casing. Initially, the liner does not have any openings through its sidewalls. The liner is installed in the wellbore, either in an open bore using packers or by cementing the liner in place, and the liner walls are then perforated. The perforations are typically created by perforation guns that discharge shaped charges through the liner and, if present, adjacent cement.
The production liner is typically perforated first in a zone near the bottom of the well. Fluids then are pumped into the well to fracture the formation in the vicinity of the perforations. After the initial zone is fractured, a plug is installed in the liner at a position above the fractured zone to isolate the lower portion of the liner. The liner is then perforated above the plug in a second zone, and the second zone is fractured. This process is repeated until all zones in the well are fractured.
Plug and perf is widely practiced, but it has a number of drawbacks, including that it can be time consuming, because perforation guns and plugs are generally run into the well and operated individually. After the frac job is complete, the plugs are removed (e.g., drilled out) to allow production of hydrocarbons through the liner.
Embodiments of the disclosure include a downhole tool including a main body, and a setting member configured to press the main body radially outwards so as to set the main body with the surrounding tubular. The setting member is made at least partially from a dissolvable material configured to dissolve in a well fluid, and the setting member defines a bore therein. The tool also includes an acid pill positioned in the bore of the setting member. The acid pill contains an acid therein, the acid pill is at least partially made from a dissolvable material configured to dissolve in the well fluid such that the acid mixes with the well fluid upon the acid pill at least partially dissolving, and the acid mixed in the well fluid increases a rate at which the dissolvable material of the setting member dissolves in the well fluid in comparison to the rate at which the dissolvable material of the setting member dissolves in the well fluid without the acid mixed therein.
Embodiments of the disclosure further include a downhole tool including a main body, a first cone received at least partially into a first end of the main body, and a second cone received at least partially into a second, opposite end of the main body. The first and second cones are configured to be advanced into the main body and adducted together so as to force the main body radially outward, and wherein the second cone comprises one or more bores therein. The tool further includes an acid pill received in one of the one or more bores, the acid pill containing an acid configured to mix with well fluid so as to increase a rate of dissolution of the second cone in the well fluid in comparison to a rate of dissolution of the second cone in the well fluid without the presence of the acid.
Embodiments of the disclosure also include a method including positioning an acid pill in a setting member of a downhole tool, deploying the downhole tool into a well, setting the downhole tool using the setting member to press at least a portion of the downhole tool radially outward, and exposing the downhole tool to a well fluid, wherein exposing the downhole tool to the well fluid causes at least a portion of the acid pill to dissolve, which exposes an acid contained within the acid pill to the well fluid such that that acid mixes with the well fluid, and wherein the acid mixed with the well fluid causes at least a portion of the downhole tool to dissolve.
The present disclosure may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings:
The following disclosure describes several embodiments for implementing different features, structures, or functions of the invention. Embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference characters (e.g., numerals) and/or letters in the various embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the embodiments presented below may be combined in any combination of ways, e.g., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, 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.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. In addition, unless otherwise provided herein, “or” statements are intended to be non-exclusive; for example, the statement “A or B” should be considered to mean “A, B, or both A and B.”
The downhole tool 100 may further include one or more acid pills 200 in the second setting member 120, e.g., in a bore 135 formed therethrough. As will be discussed herein, the acid pills 200 are configured to accelerate corrosion of the second setting member 120 and other components of the downhole tool 100. Although there are three acid pills 200 shown in
An acid may be contained within the shell 205. For example, the acid may be an acid powder 230. Examples of acid powders 230 include Sulfamic acid and Citric acid. The acid powder 230 is packed inside the shell 205 and the cap 220, which are configured to keep the acid powder 230 dry for a set amount of time in a wellbore environment. The acid may mix with (e.g., dissolve in) the well fluid, and may be configured to increase a rate at which the dissolvable material of the setting members 118, 120, the main body 102, and/or any other component of the tool 100 dissolves.
The acid pill 200 may be designed to have a predetermined release time for the acid (e.g., the acid powder 230). For example, a wall 235 of the shell 205 may have a specific thickness, which can dissolve in fluid in a certain timeframe. In other words, the acid pill 200 may be custom designed to provide a predetermined time release of the acid powder 230 in the fluid environment. Upon exposure to the well fluid, the acid powder 230 mixes with the surrounding fluid to create an acidic solution which is configured to accelerate corrosion of the second setting member 120 and other components of the downhole tool 100. As shown, the acid pill 200 is placed in the second setting member 120. In another embodiment, the acid pill 200 may be placed in other components of the downhole tool 100.
In one embodiment, the cap 220 may include a bore 225 extending partially therethrough, leaving a relatively thin section between the end of the cap 220 and the bore 225. The bore 225 thus reduces the amount of material of the cap 220 to be dissolved in order to expose the acid powder 230 to the well fluid. As a result, the section between the bottom of the bore 225 and the end of the cap 220 may dissolve and form an initial flowpath for well fluid to reach the acid powder 230. Thus, the size (or even presence) of the bore 225 may be used to adjust the predetermined release time for the acid powder 230. In another embodiment, the cap 220 and/or the shell 205 may include one or more pin holes (not shown) to reduce the amount of material in the cap 220 and/or the shell 205, which may serve a similar function of reducing the dissolution time.
The sleeve 104, the slip assembly 106, and the connection member 112 may, in some embodiments, be integral to one another, or may be formed from two or more separate pieces that are connected. Either such example is within the scope of the term “coupled to” as it relates to the sleeve 104, the slip assembly 106, and/or the connection member 112.
The slip assembly 106 may include a plurality of slip segments 113, which may be positioned circumferentially adjacent to one another. For example, a plurality of axial slots 115 may be formed circumferentially between the slip segments 113. In some embodiments, the slots 115 may not extend across the entire axial extent of the slip assembly 106, and thus bridge portions may connect together the circumferentially adjacent slip segments 113 of the slip assembly 106, e.g., proximal to a lower end 119 thereof.
Further, in an embodiment, the sleeve 104, the slip assembly 106, and the connection member 112 may together form a bore 116 extending axially through the entirety of the main body 102. In other embodiments, the bore 116 may extend partially through the main body 102 and/or may be at least partially defined by other structures.
The first and second setting members 118, 120 may be positioned at least partially in the bore 116. The first setting member 118 may initially be positioned partially within the sleeve 104, proximal to the first end 108 thereof. The second setting member 120 may initially be positioned at least partially within the slip assembly 106, e.g., proximal to the lower end 119 thereof. The setting members 118, 120 may be configured to press a section of the sleeve 104 and a section of the slip assembly 106, respectively, radially outward when moved toward one another (e.g., adducted together). The setting members 118, 120 may be adducted together via a setting tool, pressure within the wellbore above the downhole tool 100, or both.
The first and second setting members 118, 120 may be annular, with each providing a through-bore 123, 125 extending axially therethrough, which communicates with the bore 116. The first setting member 118 may additionally include an uphole-facing valve seat 127 in communication with the through-bore 123, which may be configured to receive an obstructing member, and thus seal the bore 116. The through-bore 125 of the second setting member 120 may be configured to engage the setting tool, such that the second setting member 120 may be forced upwards, towards the first setting member 118, as will be described below.
Additionally, as noted above, the second setting member 120 may include the bores 135 formed therein. The acid pills 200 may be inserted or otherwise installed in the bores 135. Some of the bores 135 may be empty during initial run-in, however, and thus the bores 135 without the acid pills may be used as bypass fluid ports, allowing fluid to flow past the second setting member 120 as the downhole tool 100 is lowered into a wellbore.
In some embodiments, the sleeve 104, at least a portion of the slip assembly 106, the connection member 112, and the setting members 118, 120 may be formed from a dissolvable material, such as magnesium, that is configured to dissolve in the wellbore after a certain amount of time, in the presence of certain chemicals, or the like.
In the embodiment of
In contrast, when the second setting member 120 advances in the bore 116, the second setting member 120 may break the slip segments 113 apart. As the second setting member 120 continues into the bore 116, the connection member 112 may also yield or shear, thereby releasing the slip segments 113 not only from connection with one another, but also with connection with the sleeve 104. The wedge action of the second setting member 120 may thus continue forcing the slip segments 113 radially outward, as well as axially toward the second end 110 of the sleeve 104. At some point, the axial surface 114 of the slip assembly 106 (e.g., of the individual slip segments 113) may engage the second end 110, as shown. Further, the slip assembly 106 may be pushed radially outward and axially over the remaining connection member 112, as shown.
Further, the outward expansion of the slip assembly 106, e.g., by breaking the slip segments 113 apart from one another, may result in the slip segments 113 anchoring into the surrounding tubular 150. This may occur before, after, or at the same time that the sleeve 104 forms at least a partial seal with the surrounding tubular. As such, a two-part anchoring, provided by the sleeve 104 and the slip assembly 106, is employed. In some situations, sand may interfere with the holding force reachable by the anchoring of the surface of the sleeve 104 with the surrounding tubular. In such situations, the holding force offered by the slip assembly 106, which may be less prone to interference by sand, may serve to hold the downhole tool 100 in position relative to the surrounding tubular.
As shown, the slip segment 113 may include a thickness that increases as proceeding toward the axial surface 114, e.g., away from the lower end 119. Further, the slip segment 113 may include engaging structures on an outer surface 300 of the slip segment 113. In the illustrated embodiment, the engaging structures include a plurality of buttons or inserts 140, which may be at least partially embedded into the slip segment 113. The inserts 140 may be formed from a suitably hard material, such that the inserts 140 are capable of being pressed into the surrounding tubular, which may be made from steel. Accordingly, the inserts 140 may be made from a carbide or ceramic material. In some embodiments, the engaging structure may include a grit coating, such as WEARSOX®, which is commercially-available from Innovex Downhole Solutions, Inc., may be applied to the outer surface, and may provide increased holding forces. In some embodiments, the engaging structure may include both the inserts 140 and the grit coating, or any other suitable material.
The sleeve 104 may include a continuous outer diameter surface. When expanded, a section of the outer diameter surface may be pressed into engagement with the surrounding tubular 150, thereby forming a metal-metal seal therewith. However, as mentioned above, sand, irregularities of the surrounding tubular, or other conditions may interfere with a complete engagement therebetween. Thus, while at least a partial seal may be maintained between the sleeve 104 and the surrounding tubular, the slip assembly 106 may provide additional holding force to maintain a stationary position of the downhole tool 100 within the surrounding tubular.
As shown in
The method 600 may include positioning an acid pill 200 in a setting member 120 of a downhole tool 100, as at 602. For example, the acid pill 200 may be installed in a bore 135 formed axially through the setting member 120. One or more bores 135 may be empty, free from acid pills, and may thus provide a fluid path therethrough, which may assist in deploying the tool 100 to a depth in a well. Further, the acid pill 200 may be modified to adjust the time it takes to dissolve the acid pill 200 to such an extent that the acid 130 therein is exposed. For example, the bore 225 may be formed and extended to a depth configured to produce a desired time delay for the release of the acid powder 130. Additionally or alternatively, pin holes or other cutaways, etc., may be provided to produce a reduced-thickness in the cap 220 or in the shell 205, so as to reduce dissolution time.
The method 600 may then include deploying the downhole tool 100 into the well, as at 604. The downhole tool 100 may be deployed as part of a wireline, slickline, or any other type of workstring, e.g., into a cased hole, open hole, or any other type of well location. The downhole tool 100 may, for example, be a frac plug that is configured to selectively isolate sections of the well from one another, enabling fluid pressure to be targeted to particular formations. In other embodiments, the downhole tool 100 may be a bridge plug, a packer, or any other type of downhole tool.
The method 600 may then include setting the downhole tool 100 using the setting member 120 to press at least a portion of the downhole tool 100 radially outward, as at 606. For example, the setting member 120 may be a cone, which may be driven into a main body 102, e.g., a slip assembly 106 thereof, so as to drive the slip assembly 106 radially outward to engage a surrounding tubular (e.g., casing, liner, or wellbore wall). In some embodiments, the setting member 120, i.e., the “second” setting member 120 referenced above is adducted toward another setting member 118, i.e., the “fist” setting member 118 discussed above, such that the two setting members 118, 120 each drive a separate portion of the main boxy radially outward. In particular, the first setting member 118 may drive the sleeve 104 of the main body 102 radially outward, and the second setting member 120 may drive the slip assembly 106 of the main body 102 radially outward.
During and/or after deploying at 604 and/or setting at 606, the method 600 may include exposing the downhole tool 100, including the setting member 120 and the acid pill 200, to well fluid, as at 608. Exposing the downhole tool 100 to the well fluid causes at least a portion of the acid pill 200 to dissolve, which exposes an acid (e.g., acid powder 230) contained within the acid pill 200 to the well fluid such that that acid mixes with the well fluid. The acid mixed with the well fluid causes at least a portion of the downhole tool 100 (e.g., a dissolvable material of the setting member 120) to dissolve, e.g., at a rate that exceeds the rate of dissolution of the at least a portion of the downhole tool 100 in the presence of well fluid without the acid mixed therein. That is, the presence of the acid hastens the dissolution of the remainder of the dissolvable part(s) of the downhole tool 100.
In some embodiments, before, during, or after exposing the downhole tool 100 to the well fluid, the method 600 may also include deploying an obstructing member 160 into the well, as at 610. The obstructing member 160 may be caught by another setting member (e.g., the “first” setting member 118) of the downhole tool 100. The obstructing member 160 being caught by the first setting member 118 may prevent fluid flow through the downhole tool 100. As a result, the well fluid in contact with the tool 100, below the obstructing member 160, may be relatively stationary, and thus the acid, when released, may form an acidic concentration that contacts the dissolvable portion of the downhole tool 100 and increases the rate of dissolution thereof, as discussed above.
As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; “uphole” and “downhole”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”
The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
This application claims priority to U.S. Provisional Patent Application having Ser. No. 62/978,022, which was filed on Feb. 18, 2020 and is incorporated herein by reference in its entirety.
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