Patent Grant
11988066
In oil and gas wellbore completion operations, perforating guns with shaped charges are commonly used to puncture holes into a wellbore casing and to create a hydraulic connection between the oil, gas, or water bearing reservoir and the wellbore. The jet of a shaped charge punches a hole in the surrounding wellbore casing and travels into the rock formation of the reservoir. The grains of the formation are destroyed, and their remains are pushed radially away from the axial center of the jet, thereby forming an elongated cavity in the rock. This cavity is also referred as “tunnel” or “perforation tunnel.” The crushed grains and the debris from the perforation jet remain in a large portion in the perforation tunnel. These remains or crushed grains can reduce the permeability of the rock and thereby reduce or even block the flow path of fluid or gas towards the wellbore. The layer of crushed grains with reduced permeability is sometimes referred to as the “skin effect” or even perforating damage.
A local underpressure (i.e., a negative pressure) can be used to extract the remains from the perforation tunnel. In general, an empty container at ambient pressure is connected to the perforating gun and deployed to the wellbore. After initiation of the perforating gun a vent or valve rapidly opens the empty container in close proximity to the perforation tunnels. The wellbore fluid will flow into the container and create a local negative pressure for the time until the container is filled. This temporary pressure drop is called “dynamic underbalance.” The local pressure in the wellbore will drop for a short period of time under the pressure of the reservoir pressure in the rock formation. This effect causes a rapid flow from the perforation tunnel, which can flush a high amount of debris from the tunnel into the wellbore and causes a cleaning of the tunnel. The amount of the dynamic underbalance may increase with the size of the opening into the ambient pressure container and the speed at which the hole is opened.
Accordingly, it may be desirable to develop a dynamic underbalance mechanism with a fast opening valve or opening to the ambient pressure container. Further it may be desirable to develop a dynamic underbalance system that can be easily connected to a wellbore tool string and easily, quickly, and reliably actuated in a wellbore environment.
An exemplary embodiment of a dynamic underbalance sub for use in a wellbore may include a sub housing, a first chamber provided in an interior of the sub housing, an opening extending through the sub housing and configured such that the first chamber is in fluid communication with an exterior of the sub housing, a second chamber provided in the interior of the sub housing, and a pressure-isolating wall provided between the first chamber and the second chamber.
A wellbore tool string for use in a wellbore may include a first wellbore tool and a dynamic underbalance sub. The wellbore tool may include a tool housing and a tool explosive provided within the tool housing. The dynamic underbalance sub may include a sub housing, a first chamber provided in an interior of the sub housing, an opening extending through the sub housing and configured such that the first chamber is in fluid communication with an exterior of the sub housing, a second chamber provided in the interior of the sub housing, a pressure-isolating wall provided between the first chamber and the second chamber, and a shaped charge ballistically coupled to the tool explosive and positioned to break or perforate the pressure-isolating wall in response to detonation of the tool explosive.
A more particular description will be rendered by reference to exemplary embodiments that are illustrated in the accompanying figures. Understanding that these drawings depict exemplary embodiments and do not limit the scope of this disclosure, the exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
Various features, aspects, and advantages of the exemplary embodiments will become more apparent from the following detailed description, along with the accompanying drawings in which like numerals represent like components throughout the figures and detailed description. The various described features are not necessarily drawn to scale in the drawings but are drawn to aid in understanding the features of the exemplary embodiments.
The headings used herein are for organizational purposes only and are not meant to limit the scope of the disclosure or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.
Reference will now be made in detail to various exemplary embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments. It is understood that reference to a particular “exemplary embodiment” of, e.g., a structure, assembly, component, configuration, method, etc. includes exemplary embodiments of, e.g., the associated features, subcomponents, method steps, etc. forming a part of the “exemplary embodiment.”
The dynamic underbalance sub 102 may further include a second chamber 112 provided in the interior of the sub housing 104. The second chamber 112 may be pressure-sealed from the first chamber 106 such that the pressure within the second chamber 112 may be maintained independently from the pressure within the first chamber 106. For example, a pressure-isolating wall 114 may be provided between the first chamber 106 and the second chamber 112 at a second chamber first end 132 of the second chamber 112.
As further seen in
In an exemplary embodiment, the second chamber 112 may be sealed at a surface so as to set a pressure of the second chamber 112 approximately equal to a surface atmospheric pressure. Accordingly, in an exemplary embodiment, the pressure in the second chamber 112 may be lower than the wellbore pressure when the dynamic underbalance sub 102 is deployed in a wellbore.
The pressure-isolating wall 114 may be configured so as to be be breached, perforated, shattered, or otherwise broken by a shaped charge 140. In an exemplary embodiment, the pressure-isolating wall 114 may include a brittle material such as glass or ceramic. In a further exemplary embodiment, the pressure-isolating wall 114 may include a borosilicate glass, a soda lime glass, or a soda lime silicate glass. In a further exemplary embodiment, the pressure-isolating wall 114 may be formed as a disc inserted into the second chamber 112. Forming the pressure-isolating wall 114 of a brittle material helps to ensure that a substantial portion of the pressure-isolating wall 114 shatters, breaks, or disintegrates when the shaped charge 140 is initiated, thereby providing a larger hole between the first chamber 106 and the second chamber 112 in order to increase the dynamic underbalance. In comparison, if the pressure-isolating wall 114 was made by a malleable material such as a metal, the shaped charge 140 may only create a small perforation hole in the pressure-isolating wall 114, thereby reducing the dynamic underbalance.
In an exemplary embodiment, the dynamic underbalance sub 102 may further include second chamber internal threads 128 formed on second interior surface 120. A lock ring 130 may be threadedly engaged with the second chamber internal threads 128 so as to abut the pressure-isolating wall 114 and keep the pressure-isolating wall 114 pressed against the shoulder 124 so as to maintain the seal between the first chamber 106 and the second chamber 112.
The dynamic underbalance sub 102 may further include sub housing external threads 136 formed on an outer surface 138 of the sub housing 104. As explained in detail herein, a container 210 may be threadedly engaged with the sub housing external threads 136.
As noted above, the dynamic underbalance sub 102 may include a shaped charge 140. The shaped charge 140 may be positioned so as to break the pressure-isolating wall 114 in response to an initiation or detonation of the shaped charge. In other words, an aiming direction of the shaped charge 140 may be aligned so as to intersect with the pressure-isolating wall 114. The shaped charge 140 may be provided in a shaped charge chamber 146 adjacent to the first chamber 106 and opposite the second chamber 112. A separation wall 144 may be provided between the shaped charge chamber 146 and the first chamber 106. When the shaped charge 140 is detonated, the resultant perforating jet will puncture the separation wall 144, propagate through the first chamber 106, and then shatter or otherwise break the pressure-isolating wall 114. The shaped charge 140 may be held in place within the shaped charge chamber 146 via a charge retainer 148 that may be threadedly engaged with the sub housing 104. The dynamic underbalance sub 102 may further include a booster 142 ballistically coupled to the shaped charge 140. The booster 142 may be ballistically coupled to an upstream first wellbore tool such as a perforating gun such that when the perforating gun is initiated, the booster 142 is also initiated, thereby initiating the shaped charge 140.
As seen in
As further seen in
The container 210 may be configured as a cylinder with an open end and a closed end. In an exemplary embodiment, the container 210, the seal element 212, the pressure-isolating wall 114, and the seal element 126 may combine to pressure-seal the second chamber 112 such that the pressure within the second chamber 112 may be maintained regardless of the pressure in the first chamber 106. The container 210 may be manufactured in a variety of lengths so as to allow the second chamber 112 to be set to a variety of volumes depending on the specific application and amount of dynamic underbalance required. In other words, a longer container 210 would result in a larger volume of the second chamber 112, thereby increasing the dynamic underbalance.
As further seen in
Because the second chamber 112 is maintained at a pressure lower than the wellbore pressure, for example, at surface atmospheric pressure, the breaking of the pressure-isolating wall 114 caused by the initiation of the shaped charge 140 creates a significant pressure differential between the first chamber 106 and the second chamber 112. The pressure differential causes the wellbore fluid to rapidly fill the second chamber 112, thereby creating the desired dynamic underbalance. This causes a rapid inflow from the wellbore into the first chamber 106 through the opening 108.
The exemplary embodiments described above may result in significant advantages over conventional dynamic underbalance systems. For example, the opening of the second chamber 112 has the velocity of a shaped charge explosion and by far exceeds the sonic velocity. In other words, opening of the second chamber 112 to create the dynamic underbalance may occur much faster than in a conventional gas pressure driven system. Additionally, the embodiments discussed above require comparatively fewer parts and a less complicated structure than conventional systems, thereby making manufacture and assembly more efficient and less expensive, as well as improving reliability in the generation of the dynamic underbalance.
Additionally,
The inflow channels 518 may allow fluid communication between the hollow interior 516 of the dynamic underbalance sub 502 and an exterior environment, i.e., the wellbore. A valve sealing block 528 may be located inside the hollow interior 516 to close the inflow channels 518 by using seals 530 axially displaced from the inflow channels 518. The sliding sleeve piston 520 may be axially displaced from the valve sealing block 528. Interior sealing block walls 532 may be located centrally in the valve sealing block 528. The interior sealing block wall 532 may have a small thickness so as to enable ballistic perforation thereof but are configured to withstand the surrounding wellbore pressure due to the relatively small surface area exposed to hydrostatic pressure. A valve actuating booster 534 may be axially displaced from the valve sealing block 528 in a direction opposite from the sliding sleeve piston 520. The valve actuating booster 534 may be an explosive pellet with a focused output or a perforation industry standard percussion initiator. The direction of detonation energy output of the valve actuating booster 534 is aimed toward the valve sealing block 528. On or more booster seals 536 may be configured to seal between the valve actuating booster 534 and the valve sealing block 528. In other words, the booster seals 536 may be provided between the valve actuating booster 534 and the valve sealing block 528 in a radial direction. The valve actuating booster 534 may be held by a booster holder 538. The booster holder 538 may be secured to the sub body 504 by using threads, as seen in
As further seen in
The valve may be actuated to an open position ballistically by piercing or perforating the interior sealing block walls 532. To activate the perforating gun 604, the detonating cord 628 may be initiated. Initiating the detonating cord 628 detonates each shaped charge 620, followed by the ballistic booster 630, which detonates and ruptures the interior sealing block walls 532. By rupturing the interior sealing block walls 532, fluid from the wellbore can rapidly pass through the inflow channels 518 and into the hollow interior 516 between the sliding sleeve piston 520 and the valve sealing block 528. With increasing pressure, the shear elements 524 may be sheared off and the sliding sleeve piston 520 may move towards the lower end 508 of the dynamic underbalance sub 502.
The dynamic underbalance sub 802 may further include a sliding sleeve 820, a sleeve holding mechanism, and a valve actuating explosive element. The sliding sleeve 820 may be arranged inside the sub body 804 such that the sub window 902 is closed and sealed from the outside environment by sleeve seals 822. One end of the sliding sleeve 820 may be configured as a plurality of hook arms 824. The hook arms 824 may be coupled or engaged with a hook shoulder 826 inside the sub body 804. Without any load the hook arms 824 are configured to have a diameter less than the inner diameter of the hook shoulder 826. An arm retainer 828 may be attached to the hook arms 824, and may be configured to spread or deflect the hook arms 824 away from a center axis and towards the hook shoulder 826. The hook arms 824 may be resiliently or elastically biased so as to return to a position in which the hook arms 824 are not engaged with the hook shoulder 826 once the arm retainer 828 is removed. The arm retainer 828 may be sealed against an inner surface of the sub body 804 by arm retainer seals 830. The arm retainer 828 may be held by a sleeve holder 832 and secured by one or more shear elements 834.
As further seen in
A valve actuating booster 844 may be positioned adjacent to the bore 838 and held in position by a booster holder 846. A second booster 848, for example, a tandem booster from a perforating gun, may be positioned separated from the valve actuating booster 844 by a booster gap 850. The valve actuating booster 844 may be a percussion initiator, a bi-directional booster, or a detonating cord.
When the valve actuating booster 844 is initiated by detonating the second booster 848, the valve actuating booster 844 produces a high amount of gas pressure. This gas pressure fills the bore 838, the distribution channels 842, and the pressure chamber 840. The pressure buildup inside the pressure chamber 840 forces the pressure chamber 840 to expand until the shear elements 834 shear off, thus allowing the arm retainer 828 to move in a direction toward the first end 806 of the dynamic underbalance sub 802. With the arm retainer 828 removed, the hook arms 824 are allowed to move towards the center axis due to the resilient/elastic bias, thereby disengaged from the hook shoulder 826. With the hook arms 824 no longer engaged with the hook shoulder 826, the sliding sleeve 820 is free to move in the axial direction. The bias force of the compressed spring 836 slides the sliding sleeve 820 toward the second end 808 of the dynamic underbalance sub 802. The movement of the sliding sleeve 820 may be stopped by the sleeve catcher 852.
Similar to the embodiments shown in
This disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems, and/or apparatuses as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. This disclosure contemplates, in various embodiments, configurations and aspects, the actual or optional use or inclusion of, e.g., components or processes as may be well-known or understood in the art and consistent with this disclosure though not depicted and/or described herein.
The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms “a” (or “an”) and “the” refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. Furthermore, references to “one embodiment”, “some embodiments”, “an embodiment” and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as “first,” “second,” “upper,” “lower” etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.
As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capabilityre, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while considering that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur—this distinction is captured by the terms “may” and “may be.”
As used in the claims, the word “comprises” and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, “consisting essentially of” and “consisting of.” Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that the appended claims should cover variations in the ranges except where this disclosure makes clear the use of a particular range in certain embodiments.
The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
This disclosure is presented for purposes of illustration and description. This disclosure is not limited to the form or forms disclosed herein. In the Detailed Description of this disclosure, for example, various features of some exemplary embodiments are grouped together to representatively describe those and other contemplated embodiments, configurations, and aspects, to the extent that including in this disclosure a description of every potential embodiment, variant, and combination of features is not feasible. Thus, the features of the disclosed embodiments, configurations, and aspects may be combined in alternate embodiments, configurations, and aspects not expressly discussed above. For example, the features recited in the following claims lie in less than all features of a single disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this disclosure.
Advances in science and technology may provide variations that are not necessarily express in the terminology of this disclosure although the claims would not necessarily exclude these variations.
The present application is a national stage application of and claims priority to Patent Cooperation Treaty (PCT) Application No. PCT/EP2021/066167 filed Jun. 16, 2021, which claims priority to U.S. Provisional Patent Application No. 63/040,979 filed Jun. 18, 2020, U.S. Provisional Patent Application No. 63/079,699 filed Sep. 17, 2020, and U.S. Provisional Patent Application No. 63/079,705 filed Sep. 17, 2020, the contents of each of which are hereby incorporated by reference in their entirety.
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| WO2021/255058 | 12/23/2021 | WO | A |
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