Patent Grant
9506309
This specification relates to the field of mineral and hydrocarbon recovery, and more particularly to the use of high-molecular weight polyglycolic acid as a primary structural member for a degradable oilfield tool.
It is well known in the art that certain geological formations have hydrocarbons, including oil and natural gas, trapped inside of them that are not efficiently recoverable in their native form. Hydraulic fracturing (“fracking” for short) is a process used to fracture and partially collapse structures so that economic quantities of minerals and hydrocarbons can be recovered. The formation may be divided into zones, which are sequentially isolated, exposed, and fractured. Fracking fluid is driven into the formation, causing additional fractures and permitting hydrocarbons to flow freely out of the formation.
It is also known to create pilot perforations and pump acid or other fluid through the pilot perforations into the formation, thereby allowing the hydrocarbons to migrate to the larger formed fractures or fissure.
To frac multiple zones, untreated zones must be isolated from already treated zones so that hydraulic pressure fractures the new zones instead of merely disrupting the already-fracked zones. There are many known methods for isolating zones, including the use of a frac sleeve, which includes a mechanically-actuated sliding sleeve engaged by a ball seat. A plurality of frac sleeves may be inserted into the well. The frac sleeves may have progressively smaller ball seats. The smallest frac ball is inserted first, passing through all but the last frac sleeve, where it seats. Applied pressure from the surface causes the frac ball to press against the ball seat, which mechanically engages a sliding sleeve. The pressure causes the sleeve to mechanically shift, opening a plurality of frac ports and exposing the formation. High-pressure fracking fluid is injected from the surface, forcing the frac fluid into the formation, and the zone is fracked.
After that zone is fracked, the second-smallest frac ball is pumped into the well bore, and seats in the penultimate sleeve. That zone is fracked, and the process is continued with increasingly larger frac balls, the largest ball being inserted last. After all zones are fracked, the pump down back pressure may move frac balls off seat, so that hydrocarbons can flow to the surface. In some cases, it is necessary to mill out the frac ball and ball seat, for example if back pressure is insufficient or if the ball was deformed by the applied pressure.
It is known in the prior art to manufacture frac balls out of carbon, composites, metals, and synthetic materials such as nylon. When the frac ball has fulfilled its purpose, it must either be removed through fluid flow of the well, or it must be destructively drilled out. Baker Hughes is also known to provide a frac ball constructed of a nanocomposite material known as “In-Tallic.” In-Tallic balls are advertised to begin dissolving within 100 hours in a potassium chloride solution.
Another style of frac ball can be pumped to a different style of ball seat, engaging sliding sleeves. The sliding sleeves open as pressure is increased, causing the sleeves to overcome a shearing mechanism, sliding the sleeve open, in turn exposing ports or slots behind the sleeves. This permits the ports or slots to act as a conduit into the formation for hydraulic fracturing, acidizing or stimulating the formation.
In one exemplary embodiment, a plurality of mechanical tools for down hole use are described, each comprising substantial structural elements made with high molecular weight polyglycolic acid (PGA). The PGA of the present disclosure is hard, millable, substantially incompressible, and capable of being used as the material of downhole tools. The PGA material of the present disclosure begins to lose structure above about 136° F. in fluid. Under a preferable thermal stress of at least approximately 250° F. the PGA material substantially loses its structure within approximately 48 hours. As the structure breaks down, the PGA tools lose compression resistance and structural integrity. After the structure breaks down, the remaining material can be safely left to biodegrade over a period of several months. The products of biodegradation, are substantially glycine, carbon dioxide, and water, and are non-toxic to humans. PGA tools provide the advantage of being usable downhole and then, when their function is accomplished, removed from the well bore through passive degradation rather than active disposal. The disclosed downhole tools made of PGA material can be initially used as conventional downhole tools to accomplish conventional downhole tool tasks. Then, upon being subjected to downhole fluids at the described temperatures, for the described times, the PGA elements lose (1) compression resistance and structural integrity which causes them to cease providing their conventional downhole tool tasks, followed by (2) passive degradation into environmentally-friendly materials. This permits them to be left in the well bore rather than having to be milled out or retrieved. Other benefits and functions are disclosed.
FIGS. 13A1, 13A2, 13A3, 13A4, 13B1, 13B2, 13C1, and 13C2 are detailed views of an exemplary embodiment of a balldrop isolation sub with PGA plugs.
One concern in the use of frac balls in production operations is that the balls themselves can become problematic. Because it is impossible to see what is going on in a well, if something goes wrong, it is difficult to know exactly what has gone wrong. It is suspected that prior art frac balls can sometimes become jammed, deformed, or that they can otherwise obstruct hydrocarbon flow when such obstruction is not desired.
One known solution to the problem of frac balls obstructing flow when obstruction is not desired is to mill out the prior art frac balls and the ball seats. But milling is expensive and takes time away from production. Baker Hughes has introduced a nanocomposite frac ball called In-Tallic.® In-Tallic® balls will begin to degrade within about 100 hours of insertion into the well, in the presence of potassium chloride.
Polyglycolic (PGA) acid is a polyester of glycolic acid. PGA has been shown to have excellent short-term stability in ambient conditions. Kuredux®, and in particular Kuredux® grade 100R60, is a biodegradable PGA with excellent mechanical properties and processability. Frazier, et al. have identified a method of processing Kuredux® PGA resin into mechanical tools for downhole drilling applications, for example for hydrocarbon and mineral recovery and structures and methods for using them.
The Applicant has made and tested PGA frac balls of the present disclosure by leaving them in room temperature tap water for months at a time. After two months, the PGA frac balls showed no signs of substantial degradation or structural changes. Applicant's PGA frac balls show no appreciable sign of degradation in ambient moisture and temperature conditions over a period of at least one year.
In one test of an exemplary embodiment, a 3.375-inch PGA frac ball withstood about 6,633 psi before structural failure. A 2.12-inch frac ball withstood 14,189 psi before failing. A 1.5-inch in frac ball withstood at least 15,000 psi for 15 minutes without failing. A failure point of the 1.5-inch frac ball was not reached because the test rig was not able to exceed 15,000 psi. Thus, a PGA frac ball is suitable for high pressure downhole hydrocarbon recovery operations, typically frac operations.
PGA frac balls can be pumped down a well bore from the surface. Typically, the initial pumping fluid is approximately 50 to 75° Fahrenheit, which condition does not have any appreciable effect on the short-term structural integrity of the frac ball. Bottom hole temperatures are known to increase with depth, as shown, for example, in
After pressure testing, a 140 g sample was placed in water at 150° F. for four days. After four days, the mass had decreased to 120 g. In a second test, a 160 g sample was placed in water at 200° F. for four days. After four days, the mass of the sample had decreased to 130 g. Acids may expedite dissolution. Kureha Corporation has provided the following formula for estimating single-sided degradation of molded PGA from thermal stress alone, measured in mm/h:
Δmm=−0.5exp(23.654−9443/K)
These time spans are consistent with the times at which conventional frac balls are drilled out, after their fracking operation blocking function has been accomplished. Therefore, the PGA frac ball can be used as a conventional frac ball and perform the fracking operation blocking function of a conventional frac ball, but can then be left in the well rather than drilling it out or other intervention by the operator. In an exemplary application, a series of frac balls is used in a fracking operation. Some prior art frac balls have sometimes stuck in their ball seat. The PGA frac ball does not stick in its ball seat. After they perform their fracking operation function, the frac balls begin to lose structural integrity, their volumes decrease slightly and they pass through their respective ball seats and move toward the toe of the well bore. The frac balls each continue to lose structural integrity until they each eventually form a soft mush without appreciable crystalline structure. This material can be left downhole without concern. Over a period of months, the PGA material biodegrades to environmentally friendly fluids and gases. In one exemplary embodiment, PGA frac balls substantially lose structural integrity in approximately 48 hours in a well with an average temperature of approximately 250° F., and completely biodegrades over several months.
It is believed degradation of the PGA in downhole conditions is primarily accomplished by random hydrolysis of ester bonds which reduces the PGA to glycolic acid, an organic substance that is not considered a pollutant and is not generally harmful to the environment or to people. Indeed, glycolic acid is used in many pharmaceutical preparations for absorption into the skin. Glycolic acid may further breakdown into glycine, or carbon dioxide and water. For example, in one test, after 91 days in fluid at 250° F., the PGA ball degraded to less than 90% of its initial weight and had biodegradability equal to cellulose subjected to similar conditions. Thus, even in the case of PGA mechanical tools that are ultimately drilled out, the remnants can be safely discarded without causing environmental harm.
Processing of the PGA material comprises in one embodiment obtaining appropriate PGA, extruding it into machinable stock, and machining it into the desired configuration. In one embodiment, Kuredux® brand PGA is purchased from the Kureha Corporation. In an exemplary embodiment, grade 100R60 PGA is purchased from Kureha Corporation through its U.S. supplier, Itochu in pellet form. The pellets are melted down and extruded into bars or cylindrical stock. In one embodiment, the extruded Kuredux® PGA resin bars are cut and machined into up to 63 different sizes of PGA balls ranging in size from 0.75 inches to 4.625 inches in 1/16-inch increments. In another embodiment, the balls are machined in ⅛ inch increments. In a preferred embodiment, the balls are milled on a lathe. The 63 different sizes correspond to matching downhole tool sliding sleeves. The smallest ball can be put down into the well first and seat onto the smallest valve. The next smallest ball can be pumped down and seat on the second smallest seat, and so forth. These ranges and processing methods are provided by way of example only. PGA frac balls smaller than 0.75 inches or larger than 4.625 inches and with different size increments can be manufactured and used. Injection molding or thermoforming techniques known in the art may also be used.
In an exemplary embodiment of the present invention as seen in
Frac sleeve 100 includes a shifting sleeve 130, which is rigidly engaged to ball seat 120. Initially, shifting sleeve 130 covers frac ports, 140. When PGA frac ball 110 is seated into ball seat 120 and high-pressure fracking fluid fills well bore 150, shifting sleeve 130 mechanically shifts, moving in a down-hole direction. This shifting exposes frac ports 140, so that there is fluid communication between frac ports 140 and hydrocarbon formation 170. As the pressure of fracking fluid increases, hydrocarbon formation 170 fractures, freeing trapped hydrocarbons from hydrocarbon formation 170.
In an alternative preferred embodiment, a frac ball 110 is pumped down into the wellbore, seated in a ball seat at the lower end of the well, and pressure is applied at the surface of the well, or other point about the casing, to volume test the casing. This enables a volume test on the casing without intervention to remove the frac ball 110, which naturally biodegrades.
Frazier, et al., have found that PGA frac balls made of Kuredux® PGA resin will begin to sufficiently degrade in approximately 48 hours in aqueous solution at approximately 250° F. so that the PGA frac ball will cease to be held upon its seat and instead pass through the seat to unblock the well bore. The substrate PGA material has a crystalline state with about a 1.9 g/cm3 density and an amorphous state with an about 1.5 g/cm3 density. It is believed that the described PGA frac ball, when pumped down the well, begins in a hard, semi-crystalline, stable state and that its immersion in hot downhole fluid, at least as hot as 136° F., causes the PGA frac ball to begin change from its hard partly crystalline state into its more malleable amorphous state. It is believed that the frac ball in the hot downhole fluid may also be losing exterior surface mass as it hydrolyzes or dissolves. These processes both reduce the frac ball's diameter and make the serially-revealed outer material of the frac ball more malleable. It is believed the degradation of PGA and downhole conditions has two stages. In the first stage, water diffuses into the amorphous regions. In the second stage, the crystalline areas degrade. Once serious degradation begins, it can progress rapidly. In many cases, a mechanical tool made of PGA will experience sudden mechanical failure at an advantageous time after it has fulfilled its purpose, for example, within approximately 2 days. It is believed that mechanical failure is achieved by the first stage, wherein the crystalline structure is compromised by hydrolysis. The resultant compromised material is a softer, more malleable PGA particulate matter that otherwise retains its chemical and mechanical properties.
Over time, the particulate matter enters the second stage and begins biodegradation proper. The high pressure of fracking on the frac ball against the seat is believed to deform the spherical PGA frac ball in its partially amorphous state and deteriorating outer surface, by elongating it through the seat and eventually pushing it through the seat. The presence of acids may enhance solubility of the frac ball and speed degradation. Increasing well bore pressure is believed to speed release of the frac ball by increasing fluid temperature and mechanical stress on the ball at the ball/seat interface.
Advantageously, PGA frac balls made of Kuredux® PGA resin have strength similar to metals. This allows them to be used for effective isolation in the extremely high pressure environment of fracking operations. Once the Kuredux® PGA resin balls start to degrade, they begin to lose their structural integrity, and easily unseat, moving out of the way of hydrocarbon production. Eventually, the balls degrade completely.
Kuredux® PGA resin or other suitable PGA can also be used to manufacture other downhole tools that are designed to be used to perform their similar conventional tool function but, rather than them being removed from the well bore by being drilled out instead deteriorate as taught herein. For example, a flapper valve, such as is disclosed in U.S. Pat. No. 7,287,596, incorporated herein by reference, can be manufactured with Kuredux, so that it can be left to deteriorate after a zone has been fracked. A composite bridge plug can also be manufactured with PGA. This may obviate the need to mill out the bridge plug after fracking, or may make milling out the bridge plug faster and easier. As disclosed herein, such elements will initially function as conventional elements; but, after being subjected to downhole fluids of the pressures and temperatures disclosed herein will degrade and then disintegrate, eliminating the need to mechanically remove them from the well.
Kuredux® PGA resin specifically has been disclosed here as an exemplary material for use in creating degradable PGA frac balls. Furthermore, while the PGA balls in this exemplary embodiment are referred to as “PGA frac balls,” those having skill in the art will recognize that such balls have numerous applications, including numerous applications in hydrocarbon recovery. Embodiments disclosed herein include any spherical ball constructed of substantially of high-molecular weight polyglycolic acid which has sufficient compression resistance and structural integrity to be used as a frac ball in hydrocarbon recovery operations and which then degrades and disintegrates, so it is not necessary to mechanically remove the ball from the well.
Cement retainer 200 may also include PGA slips 220, which may be structurally similar to prior art iron slips, but which are molded or machined PGA according to methods disclosed herein. Teeth may be added to the tips of PGA slips 220 to aid in gripping the well casing, and may be made of iron, tungsten-carbide, or other hardened materials known in the art. In other embodiments, PGA slip 220 may include a PGA base material with hardened buttons of ceramic, iron, tungsten-carbide, or other hardened materials embedded therein. Some embodiments of cement retainer 200 may be configured for use with a PGA frac ball 110.
Once sufficient set down weight has been established, applied pressure (cement) is pumped down the work string, opening the one-way check valve and allowing communication beneath the cement retainer 200. Cement retainer 200 typically has a low metallic content and in some embodiments, may require no drilling whatsoever. Rather, cement retainer 200 is left in the well bore and one or more of the PGA structural members 210 and PGA slips 220 are permitted to break down naturally. In some embodiments, the remaining metallic pieces may be sufficiently small to pump out of the well bore. In other embodiments, minimal drilling is required to clean out remaining metallic pieces.
Cement retainer 300 may have a low metallic content and in some embodiments, may require no drilling whatsoever. Rather, cement retainer 300 may be left in the well bore and PGA structural members 310, and break down naturally. In some embodiments, the remaining metallic pieces may be sufficiently small to pump out of the well bore. In other embodiments, minimal drilling is required to clean out remaining metallic pieces. Balls of any composition can be used with cement retainer 300. Some embodiments of cement retainer 300 may be configured for use with a PGA frac ball 110.
During the cementing operation, simple valve control can be accomplished through surface pipe manipulation, causing the hydraulic forces to either add or subtract weight to cement retainer 400. The operator should complete the hydraulic calculations to prevent overloading or pumping out of the retainer. The cementing process can then begin.
Cement retainer 400 may have a low metallic content and in some embodiments, may require no drilling whatsoever. Rather, cement retainer 400 is left in the well bore and one or more PGA structural members 410 are permitted to break down naturally. In some embodiments, the remaining metallic pieces may be sufficiently small to pump out of the well bore. In other embodiments, minimal drilling is required to clean out remaining metallic pieces. Some embodiments of cement retainer 400 may be configured for use with a PGA frac ball 110.
In an exemplary embodiment, PGA frac plug 500 is operated according to methods known in the prior art. For example, after performing the setting procedure known in the art, frac plug 500 remains open for fluid flow and allows wireline services to continue until the ball drop isolation procedure has started. The ball drop isolation procedure may include use of a PGA frac ball 110. Once the surface-dropped ball is pumped down and seated into the inner funnel top of the tool, the operator can pressure up against the plug to achieve isolation.
Frac plug 500 may have a low metallic content and in some embodiments, may require no drilling whatsoever. Rather, PGA frac plug 500 is left in the well bore and, in one embodiment, PGA main body 510 and PGA slip 220 are permitted to break down naturally. In some embodiments, the remaining metallic pieces may be sufficiently small to pump out of the well bore. In other embodiments, minimal drilling is required to clean out remaining metallic pieces. Some embodiments of frac plug 500 may be configured for use with a PGA frac ball 110.
In the prior art, frac plugs such as PGA frac plug 500 are used primarily for horizontal applications. But PGA frac plug 500's slim, lightweight design makes deployment fast and efficient in both vertical and horizontal wells.
Built with a one-way check valve, temporary isolation tool 600 temporarily prevents sand from invading the upper zone and eliminates cross-flow problems for example by using a PGA frac ball 110 as a sealer. After PGA frac ball 110 has been degraded by pressure, temperature or fluid, the check valve will allow fluids from the two zones to commingle. The operator can then independently treat or test each zone and remove flow-back plugs in an under-balanced environment in one trip.
Temporary isolation tool 600 may have a low metallic content and in some embodiments, may require no drilling whatsoever. Rather, temporary isolation tool 600 can be left in the well bore and PGA main body 610 and permitted to break down naturally. In some embodiments, any remaining metallic pieces may be sufficiently small to pump out of the well bore. In other embodiments, minimal drilling is required to clean out remaining metallic pieces.
Snub-nose plug 700 may be provided in several configurations with various types of valves. In one embodiment, snub-nose plug 700 may be used in conjunction with a PGA frac ball 110.
Snub-nose plug 700 may have a low metallic content and in some embodiments, may require no drilling whatsoever. Rather, snub-nose plug 700 is left in the well bore and PGA structural members 710 are permitted to break down naturally. In some embodiments, the remaining metallic pieces may be sufficiently small to pump out of the well bore. In other embodiments, minimal drilling is required to clean out remaining metallic pieces.
When built with a one-way check valve, long range frac plug 800 temporarily prevents sand from invading the upper zone and eliminates cross-flow problems, in some embodiments by utilizing a PGA frac ball 110. After PGA frac ball 110 has been degraded, the fluids in the two zones may commingle. The operator can then independently treat or test each zone and remove the flow-back plugs in an under-balanced environment in one trip.
Frac plug 800 may have a low metallic content and in some embodiments, may require no drilling whatsoever. Rather, long range frac plug 800 is left in the well bore and PGA body 810 is permitted to break down naturally. In some embodiments, the remaining metallic pieces may be sufficiently small to pump out of the well bore. In other embodiments, minimal drilling is required to clean out remaining metallic pieces.
In operation, PGA disks 910 are configured to withstand conditions such as intense heat and heavy mud loads. The isolation sub 900 is run on the bottom of the tubing or below a production packer bottom hole assembly. After the production packer is set, the disks isolate the wellbore reservoir.
After the upper production bottom hole assembly is run in hole, latched into the packer, and all tests are performed, PGA disks 910 can be drilled out, or knocked out using a drop bar, coil tubing, slickline or sand line, or they can be left to degrade on their own. Once PGA disks 910 are removed, the wellbore fluids can then be produced up the production tubing or casing string. The individual PGA pieces may then biodegrade in an environmentally-responsible manner.
For both snubbing and pump-out applications, isolation sub 1000 provides an economical alternative to traditional methods. Designed to work in a variety of conditions, isolation sub 1000 provides a dependable solution for a range of isolation operations.
Isolation sub 1000 is run on the bottom of the tubing or below a production packer bottom hole assembly. Once the production packer is set, isolation sub 1000 isolates the wellbore reservoir.
After the upper production bottom hole assembly is run in hole, latched into the packer, and all tests are performed, PGA disk 1010 can be pumped out. In an exemplary embodiment, removal comprises applying overbalance pressure from the surface or isolation tool to pump out PGA disk 1010. In other embodiments, drop bar, coil tubing, slickline or sand line can also be used. In yet other embodiments, PGA disk 1010 is left to degrade on its own. Once disk 1010 is removed, wellbore fluids can be produced up the production tubing.
FIGS. 13C1, 13C2, and 13C3 are detailed views of an exemplary isolation sub 1320. In
FIGS. 13A1, 13A2, 13A3, and 13A4 are cutaway side views of isolation sub. Shown particularly in these figures are bisecting lines A-A and B-B. Disposed around the circumference of casing 1310 are pluralities of port voids 1380, which fluidly communicate with the interior of casing 1310. Port voids 1380 are configured to threadingly receive retaining plugs 1350. A detail of port void 1380 is also included in this figure. As seen in sections A-A and B-B, two courses of port voids 1380 are included. The first course, including port voids 1380-1, 1380-2, 1380-3, and 1380-4 are disposed at substantially equal distances around the circumference of casing 1310. The second course, including port voids 1380-5, 1380-6, 1380-7, and 1380-8 are also disposed at substantially equal distances around the circumference of casing 1310 and are offset from the first course by approximately forty-five degrees.
FIGS. 13B1 and 13B2 contain more detailed side views of PGA plug 1360. In an exemplary embodiment, PGA plug 1360 is made of machined, solid-state high-molecular weight polyglycolic acid. In other embodiments, PGA plug 1360 may be machined. The total circumference of PGA plug 1360 may be approximately 0.490 inches or in the range of conventional plugs. Two 0-ring grooves 1362 may be included, with an exemplary width between about 0.093 and 0.098 inches each, and an exemplary depth of approximately 0.1 inches.
FIGS. 13C1, 13C2, and 13C3 contain more detailed side views of a retaining plug 1350. Retaining plug 1350 includes a screw or hex head 1354 to aid in mechanical insertion of retaining plug 1350 into port void 1380 (FIG. 13A4). Retaining plug 1350 also includes threading 1356, which permits retaining plug 1350 to threadingly engage port void 1380. An 0-ring groove 1352 may be included to enable plug aperture 1358 to securely seal into port void 1380. A plug aperture 1358 is also included to securely and snugly receive a PGA plug 1360. In operation, isolation sub 1300 is installed in a well casing or tubing. After the fracking operation is complete, PGA plugs 1360 will break down in the pressure and temperature environment of the well, opening ports 1320. This will enable hydrocarbons to circulate through ports 1320.
Advantageously, pumpdown dart 1400 permits threaded frac ball 1430 to be seated with substantially less pressure and fluid than is required to seat PGA frac ball 110.
The specific gravity of the balls tested was about 1.50. They were machined to tolerances held at about ±0.005 inches. Kuredux® PGA balls were field tested at a pump rate of 20 barrels per minute and exhibited high compressive strength, but relatively fast break down into environmentally friendly products.
Frac Ball Example 1
A first test was performed with a 3.375 inch frac ball. Pressurizing was begun. Pressure was increased until, upon reaching 6633 psi, the pressure dropped to around 1000 psi. Continued to increase pressure. The ball passed through the seat at 1401 psi. The 3.375 inch frac ball broke into several pieces after passing through the seat and slamming into the other side of the test apparatus.
Frac Ball Example 2
A second test was performed with a 2.125 inch frac ball. Pressurizing was begun. Upon reaching 10,000 psi, that pressure was held for 15 minutes. After the 15 minute hold, pressure was increased to take the frac ball to failure. At 14,189 psi, the pressure dropped to 13,304 psi. Continued to increase pressure until the ball passed through the seat at 14,182 psi.
Frac Ball Example 3
A third test was performed with a 1.500 inch frac ball. Pressurizing was begun. Upon reaching 10,000 psi, that pressure was held for 15 minutes. After the 15 minute hold, pressure was increased to 14,500 psi and held for 5 minutes. All pressure was then bled off. Did not take this ball to failure. Removing the ball from the seat took very little effort; it was removed by hand. Close examination of the frac ball revealed barely perceptible indentation where it had been seated on the ball seat.
In one preferred embodiment, Applicant's PGA ball operates downhole from formation pressure and temperature to fracking pressures up to 15,000 psi and temperatures up to 400° F.
Frac Ball Pressure Testing Weight Loss
After pressure testing, two different pieces of the 3⅜ inch frac ball were put into water and heated to try to degrade the pieces. The first piece weighed 140 grams. It was put into 150° F. water. After four days, the first piece weighed 120 grams.
The second piece weighed 160 grams. It was placed in 200° F. water. After four days, the second piece weighed 130 grams.
In the absence of fluid flow adjacent the ball, the ball's temperature will be substantially determined by the temperature of the formation of the zone where the ball is seated. An increase in pressure upon the ball due to fracking may produce an increase in adjacent downhole temperature, and, in addition to other factors, such as how far removed the ball is from the fracking ports, increase downhole fluid temperature adjacent the ball. For example, increasing downhole pressure to 10,000 psi may produce a downhole fluid temperature of 350° F. and increasing downhole pressure to 15,000 psi may produce a 400° F. temperature. Because degradation is temperature dependent, higher temperatures will cause degradation to begin more quickly and for the degradable element to fail more quickly. Duration from initiation of fracking until the PGA frac ball fails will generally decrease with increasing temperature and pressure. Accordingly, for a given desired blockage duration, other conditions being equal, desired PGA frac ball diameters increase with increasing pressure and with increasing temperature.
Fluid flow of fluid from the surface adjacent to the ball typically cools the ball. Accordingly, it is believed flowing fracking fluid close to the ball, cools the ball. These are factors which the operator may consider in determining preferable ball/seat overlap and ball size for the particular operation.
Taking these factors into account in choice of frac ball size, PGA frac balls for example, are useful for pressures and temperatures up to at least 15,000 pi and 400° F., it being understood that pressure and temperature effects are inversely related to the duration of time the PGA frac ball must be exposed to the downhole fluid environment before it is sufficiently malleable and sufficiently deteriorated to pass through the seat. It is believed the PGA frac ball undergoes a change from a hard crystalline material to a more malleable amorphous material, which amorphous material degrades or deteriorates, causing the ball to lose mass. These processes operate from the ball's outer surface inward. The increasing pressure of fracking increases downhole fluid temperature and causes shearing stress on the conical portion of the ball abutting the seat. It is believed as these several processes progress, they cooperate to squeeze the shrinking, more malleable ball which is under greater shear stress through the seat. It is believed the described downhole tools comprised of the described materials will initially function as conventional downhole tools and then deteriorate as described herein. It is believed that the described several processes function together to accomplish the change from the initial hard dense frac ball blocking the well bore by sealing against the seat to the more malleable less dense frac ball which has passed through the seat, unblocking the well bore. At greater pressure and temperatures, deterioration occurs at a more rapid rate. Degradation produced by higher pressure and higher temperature for a shorter time is believed to be accomplished by processes which are similar to degradation produced at a lower pressure and lower temperature for a longer time. These are deterministic processes which produce reliably repetitive and predictable results from similar conditions. Knowledge of these processes can be used to calculate the duration for different size frac balls will pass through the seat of a plug at a particular depth, pressure and temperature. This permits the operator to ball, which will seal the wellbore by blocking the plug for the operators chosen duration. This is advantageous in field operations because it permits production operations to be tightly and reliably scheduled and accomplished.
The size of the ball relative to the seat is selected to produce the desired bridge plug conduit blockage duration for the particular well situation in light of the conditions where the subject bridge plug will be positioned. The lower the temperature of the formation at the location where the where the bridge plug will be used, the smaller the preferred size of the ball relative to the seat for a given desired duration of bridge plug conduit blockage. The higher the temperature of the formation where the bridge plug will be used, the larger the preferred size of the ball relative to the seat for a given desired duration of bridge plug conduit blockage. Likewise, the longer the period of time desired for the ball to block the conduit by remaining on the seat, the larger the preferred size of the ball relative to the seat for a given desired duration of bridge plug conduit blockage. The shorter the period of time desired for the ball to block conduit by remaining on the seat, the smaller the preferred size of the ball relative to the seat for a given desired duration of bridge plug conduit blockage.
Applicant's balls and methods of using them in downhole isolation operations comprise providing a set of balls to an operator which set has balls of predetermined and predefined sizes. An exemplary set of balls comprises balls within the range of 1.313 inches to 3.500 inches, which balls provide the operator with predefined and predetermined size differences, either uniform size differences or nonuniform size differences. For example, the size differences may be 1/16 inch or ¼ inch between each ball size. For example, for an exemplary useful set of balls may comprise balls sized 1.313; 1.813; 1.875; 1.938; 2.000; 2.500; 2.750; 2.813; 2.938; 3.188; 3.250; and 3.500.
Applicant's method of choosing an appropriate ball size for use with a particular isolation tool to be used at a particular depth in a particular well includes use of the decision tree disclosed herein, which decision tree for a particular operation may include consideration of some of times, pressures, temperatures, clearance through higher isolation tools with seats, and the size of the particular isolation tool's seat to determine the desired ball/seat overlap, and thus the appropriate ball size. Times may include time of the ball on the seat, fracking time, time for the ball to pass through the seat, time to substantial ball deterioration and time for substantially total ball disintegration into non-toxic byproducts. Pressures may include pressure on the ball at the particular isolation tool prior to fracking, pressure on the ball during fracking, and pressure on the ball after fracking. Temperatures may include temperature at the particular isolation tool prior to fracking, temperature at the ball during fracking, and temperature at the ball after fracking. Required clearance through the seats of higher isolation tools and consideration of the number of seats through which the ball will pass before reaching the target seat on the target isolation tool. Preferably at least about 0.4 inches of clearance will be provided between the ball and the higher seat through which the ball must pass before reaching the target seat. The size of the target seat determines the size of the ball to provide the desired ball/seat overlap, which Applicant's decision tree determines is most preferable for the particular operation. The data of
Applicant's preferred apparatus and method includes providing an appropriate set of balls to the operator at the well site prior to the operator needing the balls for the operation. The balls in the set of balls have predefined and predetermined sizes selected to be appropriate for the operator's needs at the specific well. Although different arbitrary sizes of balls can be provided, Applicant's method includes providing the operator with balls which have a uniform size difference between the balls and which size difference is chosen to most likely provide ball sizes appropriate for the operator's needs.
In a previous example, Kuredux® PGA frac balls are provided in sizes between 0.75 inches and 4.625 inches, to facilitate operation of frac sleeves of various sizes. In other embodiments, balls may be provided in increments from about 1 inch up to over about 7 inches. It is advantageous to provide to the operator a set of balls which have uniform incremental sizes, to ensure the operator has on hand balls appropriate to the operator's immediate needs and preferences. In some applications, ball sizes in the delivered set are preferably increased in one-eighth inch increments. In other applications, the incremental increase in ball sizes in the delivered set is preferably in sixteenths of an inch. Thus, in appropriate cases, a set of balls is delivered to the operator appropriate for fracking the desired zones with a single run of frac balls which are immediately available to the operator due to having been previously provided the operator in a predetermined set of frac balls. It is typical for an operator to frac more than 12 and less than 25 zones with a single run of frac balls. A set of PGA frac balls delivered to a well site may comprise between 10 and 50 frac balls. A preferable set of PGA frac balls delivered to a well site may comprise 12 to 25 frac balls. If the operator has on hand an appropriate set of frac balls, the operator may frac up to 63 zones with a single run of frac balls.
Other conditions and measurements being equal, smaller balls can resist more pressure for longer than larger balls having the same ball/seat overlap. In some embodiments, the overlap or difference between seat diameter and ball diameter may be about ⅛ inch or about ¼ inch. In one embodiment, the balls at or over 3″ in diameter have about ¼ inch smaller seats, and those under 3″ in diameter have about ⅛ inch difference. If a time longer than about 10-15 hours until frac completion and/or downhole temperature conditions exceed about 275°, then ball diameters, and overlap of the ball over the seat, may be increased accordingly to increase the duration of the ball on the seat.
The operator, being aware of depths and formation conditions at each of the isolation plug locations in the wellbore, and deciding upon how many isolation plugs are to be used to produce the well, determines desired ball sizes and seats for each of the isolation plugs to be used in the well from the balls available in the set of balls at the well site using the methods described herein. Upon determining desired ball sizes for the several isolation plugs from the immediately available set of preselected and predetermined balls, the operator uses the disclosed decision tree factors to determine the appropriate ball for each isolation plug from the preselected appropriate set of balls, and uses each chosen ball for its target seat in its target isolation valve in the fracking or other isolation tool operation at each target formation location. This method of having a pre-delivered set of balls appropriate for the well at the well site, and method for selecting appropriate balls from the pre-delivered set of balls provides the operator with a convenient, timely and efficient method for having appropriate balls immediately available, determining ball sizes appropriate for production operations at the well, selecting appropriate balls from the set of balls, and using them in the production operation at the well.
In some embodiments of some isolation valves, such as a frac sleeve, multiple balls are used with the isolation tool. For example, some tools require four frac balls to operate a frac sleeve. In those cases, a plurality of identically sized PGA frac balls, 110 are provided and available and are used.
5½ Inch Snub Nose Structural Integrity Test
A 5½ inch snub nose was tested in a 48 inch length tubing. The test used a single pack-off element with bottom shear at about 32,000 lbs. The PGA elements of this tool were: mandrel part 1, load ring part 2, cones part 4, and bottom part 7 (7a and 7b), the part numbers being as identified on
Once the plug was assembled and installed on the setting tube, it was lowered into the 5.5 inch, 20 lb. casing. The setting process then began. The plug was successfully set with a 31.5 K shear. A ball was dropped onto the mandrel and the casing was pumped into the test console. Top side pressure was then increased to 5000 psi momentarily to check for leaks, either from the test fixture or the pressure lines. No leaks were evident and the top side pressure was then increased to 6500 psi for 15 minute duration. Pressure was then increased top side to 8000 psi for 15 minute duration. Upon completion of the 8000 psi hold, pressure was increased top side 10,000 psi for a 20 minute duration. Minimal pressure loss was evident on the top side of the plug. This is attributed to additional pack-off and mandrel stroke due to the fact that no sign of fluid bypass was evident on the bottom side of the plug. Total fluid capacity of the casing was less than 2.5 USG, pressure loss evident top side at the plug totaled less than 1 cup. Assembly pressure was then bled down and testing was completed.
Upon removal of the test cap, there was no sign of eminent failure. The slips had broken apart perfectly and were fully engaged with the casing wall. There was also no sign of element extrusion or mandrel collapse. Everything performed as designed. Similar testing was done on a 4½ inch plug with similar results.
Set forth in
In one preferred embodiment of the down hole tool structural elements made from PGA substantially degrade to release the slips from the slip's set position in a temperature range of about 136° to about 334° F. in between one to twelve hours, in a substantially non-fluid flow condition. The fluid may be partially or substantially aqueous, may be brine, may be basic or neutral, and may be at ambient pressure or pressures. Maximum pressure varies according to the structural requirements of the PGA element as shown by the pressure limitation curve of
Some prior art degradable downhole tool elements, upon dissolution, leave behind incrementally unfriendly materials, some in part due to the fluids used to degrade the prior art elements.
In downhole use of downhole tool elements comprised of PGA as described herein, the PGA elements initially accomplish the functions of conventional non-PGA elements and then the PGA elements degraded or disintegrated into non-toxic to humans and environmentally-friendly byproducts as described herein.
As set forth herein, when the above described downhole tool elements or other downhole tool elements comprised of PGA and its equivalents are placed within the above conditions, they will typically first perform their conventional downhole tool element function and then undergo a first breakdown. This first breakdown loosens and ultimately releases the non-PGA elements of the plug from the PGA elements of the plug. This includes release of the slips which press against the inner walls of the production tubing to hold the downhole tool in place. Release of the slips permits displacement of down hole tool through the well bore. Typically, continued downhole degradation then results in substantial breakdown of the PGA elements into materials which are non-toxic to humans and environmentally friendly compounds. For example, in typical down hole completion and production environments, and the fluids found therein, PGA will break down into glycerin, CO2 and water. These are non-toxic to humans and environmentally friendly. The slips are usually cast iron, shear pins usually brass, and the elastomer usually rubber. However, they may be comprised of any other suitable substances. These elements are constructed structurally and of materials known in the prior art.
Some prior art downhole tool elements must be mechanically removed from the well bore, such as by milling them out or retrieving them. The described PGA element does not need to be mechanically removed. Some prior art downhole tool elements require a turbulent flow of fluid upon them for them to degrade or deteriorate. The described PGA elements degrade or deteriorate in the presence of still downhole fluid. The described PGA elements primarily only require the presence of a heated fluid to begin deteriorating. This is a substantial advantage for PGA-comprised downhole tool elements.
Some prior art degradable downhole tool elements require a high or low PH fluid or require a solvent other than typical downhole fluid to promote degrading. The described PGA elements degrade or deteriorate in the presence of typical hot downhole fluid and without the necessity of a high or low PH fluid or a solvent other than typical hot downhole production fluid. Fluids the described GPA material degrades in include hydrocarbons, water, liquid gas, or brine. In one embodiment, no other substances, for example, metals or ceramics, are mixed with the PGA in the element. PGA has been found to degrade in non-acidic oil, liquid gas, brine or any typical down hole fluid without needing a significant turbulent flow of the down hole fluid in the proximity of the structure element to begin the disintegration. It is especially useful that acidic fluids are not necessary for its disintegration.
This is advantageous because some prior art elements are primarily only quickly dissoluble down hole in the presence of a substantial flow of down hole fluid or in the presence of acidic fluids, conditions which require use of coiled tubing or other tool and activity to create conditions for degrading their elements. The disclosed embodiment is advantageously used to perform its mechanical functions and then degrade without further investment of time, tools or activity.
The PGA downhole elements described herein are advantageously stable at ambient temperature and substantially stable in downhole fluid at downhole fluid temperatures of up to about 136° F. PGA downhole elements begin to degrade or deteriorate in downhole fluid at downhole temperatures of above 136° F., and preferably in the range of from 150° F. to 300° F. Fracking operations pressurize the downhole fluid, and the higher pressures cause higher temperatures. Thus, the PGA element has the strength and incompressibility to be used as a conventional downhole tool element in a high pressure of fracking operation, and the high pressure of fracking causes the downhole fluid temperature to rise, which high downhole fluid temperature initiates degradation of the PGA element which allows production of the well without drilling out or retrieving the tool.
The predictable duration of time between PGA elements being immersed in the drilling fluid and the elements degrading is a useful function of the described element. The described PGA elements sufficiently degrade or deteriorate after their fracking function is completed so they fail their convention tool element function and production can proceed without being impeded by the elements remaining in the bore hole within about five hours to about two days. For example, a preferred time for PGA frac balls to fail by passing through their ball seat is from between about five to six hours to about two days. The time to failure is determinable from the teachings herein and experience.
In one aspect, a machinable, high molecular weight hydrocarbon polymer of compressive strength between about 50 and 200 MPa (INSRON 55R-4206, compression rate 1 mm 1 min, PGA 10×10×4 (mm), 73° F. to 120° F.) may be used as the precursor or substrate material from which to make or prepare plug balls, mandrels, cones, load rings, and mule shoes or any of those parts degradable in typical downhole fluids in high pressure and temperature conditions. In another aspect, one or more of such elements of a downhole plug will decay faster than typical metallic such elements, typically within several days after being placed within the downhole environment. In a more specific aspect, the polyglycolic acid as found in U.S. Pat. No. 6,951,956, may be the polymer or co-polymer and used as the substrate material, and may include a heat stabilizer as set forth therein. Polyglycolic acid and its properties may have the chemical and physical properties as set forth in the Kuredux® Polyglycolic Acid Technical Guidebook as of Apr. 20, 2012, and the Kuredux® PGA Technical Information (Compressive Stress) dated Jan. 10, 2012, from Kureha Corporation, PGA Research Laboratories, a 34-page document. Both the foregoing Kureha patent and the Kuredux® technical publications are incorporated herein by reference. Kuredux® PGA resin is certified to be a biodegradable plastic in the United States by the Biodegradable Plastics Institute and is a fully compostable material satisfying the ISO 14855 test protocol.
In a preferred embodiment, Applicant prepares the structural elements of downhole isolation tools comprising, without limit, the mandrel, load rings, cones, and mule shoes from Kuredux® 100R60 PGA resin. This is a high density polymer with a specific gravity of about 1.50 grams per cubic centimeter in an amorphous state and about 1.70 grams per cubic centimeter in a crystalline state, and a maximum degree of crystallinity of about 50%. In a preferred embodiment, the Kuredux® is used in pellet form as a precursor in a manufacturing process, which includes the steps of extruding the pellets under heat and pressure into a cylindrical or rectangular bar stock and machining the bar stock as set forth herein. In one embodiment of a manufacturing method for the structural elements that use the polymer and, more specifically, the PGA as set forth herein, extruded stock is cylindrically shaped and used in a lathe to generate one or more of the structural elements set forth herein.
The lathe may be set up with and use inserts of the same type as used to machine aluminum plug or down hole parts that are known in the art. The lathe may be set up to run and run to a depth of about 0.250 inches. The lathe may be set to run and run at an IPR of 0.020 inches (typically, 10-70% greater than used for aluminum), during the roughing process. The roughing process may run the PGA stock dry (no coolant) in one embodiment and at a spindle speed (rpm) and a feed rate that are adjusted to knock the particles into a size that resembles parmesan cheese. This will help avoid heat buildup during machining of the structural elements as disclosed herein.
In a finishing process, the IPR may be significantly reduced, in one method, to about 0.006 inches, and the spindle speed can be increased and the feed rate decreased.
In one or more aspects of this invention, the structural elements of the plug and the ball are made from a homogenous, non-composite (a non-mixture) body configured as known in the art to achieve the functions of a ball in one embodiment, a mandrel in another, support rings in another, and a mule shoe in another. This homogenous non-composite body may be a high molecular weight polymer and may be configured to degrade in down hole fluids between a temperature of about 136° F. and about 334° F. It may be adapted to be used with slip seals, elastomer elements, and shear pins, as structurally and functionally found in the prior art, and made from materials found in the prior art.
In certain aspects of Applicant's devices, the homogenous, non-composite polymer body will be stable at ambient temperatures and, at temperatures of at least about 200° F. and above, will at least partially degrade to a subsequent configuration that unblocks a down hole conduit and will further subsequently degrade into products harmless to the environment.
PGA is typically a substantial component of these structural elements and, in one embodiment, homogenous. Generally, it has tensile strength similar to aluminum, melts from the outside in, is non-porous, and has the crystalline-like properties of incompressibility. Although this disclosure uses specific PGA material and specific structural examples, it teaches use of materials other than PGA materials which degrade or deteriorate in similar downhole conditions or conditions outside the particular range of PGA. It further teaches that downhole tools of various structures, functions, and compositions, whether homogeneous or heterogeneous, may be usefully used within the scope of the disclosure to obtain the described useful results.
In one embodiment, heat stabilizers are added to the PGA or other substrate material to vary the range of temperatures and range of durations of the downhole tool element's described functions. Greater downhole depths and fracking pressures produce greater downhole fluid temperatures. An operator may choose to use the described degradable elements, modified to not begin degrading as quickly or at as low a temperature as described herein. Addition of a heat stabilizer to the PGA or other substrate material will produce this desired result.
Although some of the described embodiments are homogenous, the downhole elements may be heterogeneous. Fine or course particles of other materials can be included in a substrate admixture. Such particles may either degrade more quickly or more slowly than the PGA or other substrate material to speed or slow deterioration of the downhole elements as may be appropriate for different downhole conditions and tasks. For example, inclusion of higher melting point non-degradable material in a PGA ball is expected to delay the ball's passage through the seat and delay the ball's deterioration. For example, inclusion of a heat stabilizer in a PGA ball is expected to delay the ball's passage through the seat and delay the ball's deterioration. For example, inclusion of materials which degrade at temperatures lower than temperatures at which PGA degrades or which degrade more quickly than PGA degrades is expected to speed a ball's passage through the seat and speed a ball's deterioration. These teachings are applicable to the other downhole elements described herein and to other downhole tools generally.
The predictable duration of time from the temperature initiated deterioration beginning to degrade the element sufficiently that it fails, cases to perform its conventional tool function, under given conditions as taught herein is advantageous in field operations. The degradable element's composition, shape, and size can be varied to obtain a reliable desired duration of time from temperature-initiated deterioration to tool failure. In an embodiment, there are one or more coatings on the element. These coatings may be used to predictably vary the time to the element's functional dissolution malleability and dissolution.
In specific embodiments, the structural elements set forth herein are configured to be made from a high molecular weight polymer, including repeating PGA monomers include the tools seen in
While measured numerical values stated here are intended to be accurate, unless otherwise indicated the numerical values stated here are primarily exemplary of values that are expected. Actual numerical values in the field may vary depending upon the particular structures, compositions, properties, and conditions sought, used, and encountered. While the subject of this specification has been described in connection with one or more exemplary embodiments, it is not intended to limit the claims to the particular forms set forth. On the contrary, the appended claims are intended to cover such alternatives, modifications and equivalents as may be included within their spirit and scope.
This continuation-in-part application claims priority to U.S. patent application Ser. No. 13/895,707, filed May 23, 2013; U.S. patent application Ser. No. 13/894,649, filed May 15, 2013, which is a continuation of and claims priority to U.S. patent application Ser. No. 13/843,051, filed Mar. 15, 2013; and which claims the benefit of U.S. Provisional Application 61/648,749, filed May 18, 2012; U.S. Provisional Application 61/738,519, filed Dec. 18, 2012. All of the foregoing and US Patent Publication No. 2010/0155050, published Jun. 24, 2010, which is now U.S. patent application Ser. No. 12/317,497, filed Dec. 23, 2008, are incorporated herein by reference. U.S. Pat. No. 6,951,956 is also incorporated herein by reference.
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