Patent Application
20160160642
None.
The invention relates, in general, to accurately determining the distribution, dimension and geometry of hydraulically-induced fractures and fracture networks, i.e., “mapping,” in a subterranean reservoir. More particularly, the invention relates to methods and apparatus for creating detectable signals at a plurality of locations within the fractures and fracture networks with acoustic particles that are capable of emitting detectable signals.
Hydraulic fracturing is used to improve well productivity by hydraulically injecting fluid under pressure into a selected zone of a reservoir. The pressure causes the formation and/or enlargement of fractures in this zone. Proppant is typically positioned in the fractures with the injected fluids before pumping is halted to prevent total closure. The proppant thus holds the fractures open, creating a permeable and porous path, open to fluid flow from the reservoir formation to the wellbore. Recoverable fluids, such as, oil, gas or water are then pumped or flowed to the surface.
The information on the geometry of the generated hydraulic fracture networks in a given reservoir formation is critical in determining the design parameters of future fracture treatments (such as types and amounts of proppant or fluids to use), further well treatments to be employed, for the design of the future wells to be drilled, for managing production, etc. Therefore, there is a need for accurate mapping of the fractures. The methods typically used include pressure and temperature analysis, seismic sensor (e.g., tilt-meter) observational analysis, and micro-seismic monitoring of fracture formation during fracturing processes. Each of these methods have their drawbacks, including complicated de-convolution of acquired data, reliance on assumed parameters, educated “guesswork” as to the connectivity of various mapped seismic events, and problems associated with reliance on mapping-while-fracturing methods, namely, measuring the shape of the fractures during formation (rather than after closure or during production), measuring fractures which may not be conductive to the wellbore, acoustic “noise” from the fracturing procedures, and an inability to distinguish between seismic events that are caused by fracture formation or other processes.
Methods have been suggested for mapping fractures using explosive, implosive or rapidly combustible particulate material added to the fracturing fluid and pumped into the fracture during the stimulation treatment, namely, in U.S. Pat. No. 7,134,492 to Willberg, et al. Similar methods are disclosed in Autonomous Microexplosives Subsurface Tracing System Final Report, Sandia Report (SAND2004-1415), Warpinski, N. R., Engler, B. P., et al., (2004). However, the suggested practices have significant drawbacks, including the transport and handling of explosive particles at the surface and during pumping, exposure of explosive particles to very high pressures, treatment and wellbore fluids and chemistry, difficulty in controlling the timing of the explosions given their lengthy exposure to fracturing fluids, exposure of particles to significant and high pressures during fracturing, the risk of explosive particles becoming stuck in the well completion string, pumping and mixing equipment, etc. Further, some of the proposals require the inclusion of power sources, electronics, etc., in the injected particles which may be impractical at the sizes required to infiltrate a fracture and proppant and are relatively expensive.
It is therefore an object of the present invention to provide a new approach to evaluating hydraulic fracture geometry.
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
It should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures. Where this is not the case and a term is being used to indicate a required orientation, the specification will make such clear. Upstream, uphole, downstream and downhole are used to indicate location or direction in relation to the surface, where upstream indicates relative position or movement towards the surface along the wellbore and downstream indicates relative position or movement further away from the surface along the wellbore, unless otherwise indicated.
Even though the methods herein are discussed in relation to a vertical well, it should be understood by those skilled in the art that the system disclosed herein is equally well-suited for use in wells having other configurations including deviated wells, inclined wells, horizontal wells, multilateral wells and the like. Accordingly, use of directional terms such as “above”, “below”, “upper”, “lower” and the like are used for convenience. Also, even though the discussion refers to a surface well operation, it should be understood by those skilled in the art that the apparatus and methods can also be employed in an offshore operation.
While the making and using of various embodiments of the present invention are discussed in detail below, a practitioner of the art will appreciate that the present invention provides applicable inventive concepts which can be embodied in a variety of specific contexts. The specific embodiments discussed herein are illustrative of specific ways to make and use the invention and do not limit the scope of the present invention.
Further disclosure regarding micro-seismic event creation during or after fracturing of a formation, as well as detection of these events, mapping, and other processes discussed herein can be found in International Application No. PCT/US2012/32822, to Ersoz, filed Apr. 10, 2012, which is incorporated herein in its entirety for all purposes.
An exemplary hydraulic fracture (10) is formed by pumping a fracturing fluid (F) into the treatment well (12) at a rate sufficient to increase downhole pressure to exceed the fracture gradient of the reservoir formation (14). The increased pressure causes the formation rock (14) to fracture, which allows the fracturing fluid (F) to enter and extend the fracture further into the formation (14). The fracturing of formation rock (14) and other events often related to expansion or relaxation of formation rock that change the in situ stress profile and pore pressure distribution create a plurality of micro-seismic events (16).
As used herein, the term “micro-seismic event” (and similar) refers to any event that causes a small but detectable change in stress and pressure distributions in a reservoir formation, including those caused by slippages, deformation, and breaking of rock along natural fractures, bedding or faults, creation of fractures or re-opening of fractures, and events artificially created by fracturing operations or caused by an explosion, implosion, exothermic reaction, etc.
Each micro-seismic event (16) generates seismic, or acoustic, waves (18). The waves generated may be of various types such as body waves, surface waves and others. For the purposes of this invention, the body waves are the main point of interest. There are two types of body waves: compression, pressure or primary waves (called P-waves), and shear or secondary waves (called S-waves). The P-waves and S-waves travel through the earth formations at speeds governed by the bulk density and bulk modulus (rock mechanical properties) of the formation. The rock mechanical properties of the formation vary according to mineralogy, porosity, fluid content, in situ stress profile and temperature.
The terms “seismic wave,” “seismic pulse,” “acoustic wave,” “acoustic pulse” and similar, as used herein, refer to detectable and measurable P- and S-waves caused by the micro-seismic event. Each type of wave may be detected and measured by corresponding sensor equipment, generally referred to herein as “seismic sensors” or “acoustic sensors” or similar.
The waves (18) propagate away from each micro-seismic event (16) in all directions and travel through the reservoir formations. These waves are detected by a plurality of seismic sensors, such as seen at (20) and (21). These sensors (or receivers), which are capable of detecting and measuring micro-seismic events, can be of any type, such as seismographs, tilt meters, piezoelectric sensors, accelerometers, transducers, ground motion sensors, multi-axis sensors, geophones and/or hydrophones. Seismic sensors and sensor arrays are commercially available and known in the industry. The seismic sensors are sensitive instruments capable of detecting micro-seismic events (16). The seismic sensors can be placed in a wellbore of one or more observation or monitoring wells (22). Sensors can also be placed at or near the surface (24), preferably in shallow boreholes (26) drilled for that purpose. A typical shallow borehole (26) for such a purpose is ten to forty feet deep.
Micro-seismic monitoring is based on technologies with its origins rooted in earthquake seismology (that is, large amplitude events). More recently, with the development of extremely sensitive borehole sensor array systems and surface monitoring equipment, it has become possible to detect even very small amplitude events (micro-seismic events) that cause relatively small changes in stress and pressure distributions from considerable distances. In addition to the sensor technology, data acquisition, telemetry and processing systems have been developed to handle these small amplitude events. Consequently, micro-seismic events, which occur at much higher frequencies than surface seismic surveys, can be measured, even in the presence of “noise” caused by other surface and downhole activities.
The recorded P- and S-wave data is analyzed, in a process referred to as “mapping” “imaging,” which calculates locations of the events in 3-dimensional reservoir space. Typically, a location information solution based on a statistical best-fit method is used to map an event in terms of distance, elevation and azimuth. Analysis of the recorded and measured seismic events will not be discussed herein in detail, as it is known in the art. Software for analyzing and displaying the measurements and results are commercially available. For example, such products and services are available from Halliburton Energy Services, Inc., under the brand names such as FracTrac® and TerraVista® visualization and interpretation. Further information, including on seismic event detection and analysis can be found in the following documents which are each incorporated herein by reference for all purposes: U.S. Pat. No. 7,908,230 to Bailey, U.S. Pat. No. 7,967,069 to Beasley, U.S. Pat. No. 7,874,362 to Coates, U.S. Pat. No. 7,830,745 to Suarez; and Patent Application Publication Nos. WO 2008/118986 to Coates, and 2007/105167 to Lafferty.
The accuracy of mapping recorded events is dependent on the number of sensors spaced across the reservoir and by the distance of the sensors from the measured events. It is beneficial, therefore, to place sensors in the treatment well. The current micro-seismic monitoring methods suffer from the fact that the entire process takes place during hydraulic fracturing. Therefore the recorded data include the “noise” of the fracturing process and the results (mapped event locations) are of opened fractures (rather than propped or effective fractures).
Currently, there is no way to accurately differentiate which events correspond to opened fractures, propped fractures and effective fractures. The methods described herein make it possible to map the effective (propped and connected) fracture space by separating the mapping survey from fracture formation process. Further, the methods described herein improve the quality and accuracy of the mapping process by allowing sensors to be placed in the treatment well and without interference from hydraulic fracturing “noise.” Other improvements will be discussed in the following sections.
Sensors (20) and (21) detect and acquire P- and S-wave data that are generated by micro-seismic events (16) and travelled through the formations. The data is typically transferred to data processing systems (25) for preliminary well site analysis. In-depth analysis is typically performed after the raw data is collected and quality-checked. After final analysis, the results (maps of the fracture networks) are invaluable in development planning for the reservoir and field, and in designing future hydraulic fracturing jobs.
The methods presented herein use similar terminology to refer to similar types of particles, etc. The system will be described using the terms: Attachment Site (AS) particles (or Attachment Sites), Type-1 particles (T1), Type-2 particles (T2) and Type-3 particles (T3). Further, for each particle “type,” a plurality of “species” can be employed, designated, for example, as AS-x, AS-y, AS-z, each suffix representing a different species of particle. The species of any one particle correspond to common species of the other particles. For example, AS-x particles will interact with T1-x and T2-x particles and not with T1-y and T2-y particles. Details are provided below.
The AS particles have a functionalized surface layer or coating (102) which is selected and designed to allow attachment of pre-selected Type-1 and Type-2 particles. The process of attracting or attaching of the particles (AS, T1, T2, etc.) is primarily based on chemical and physical properties of the functionalized surface layer.
The Attachment Site particles (100) are preferably pumped with the treatment fluid (F) and proppant particles (44) into the fracture network (40) and entrapped within the effective fractures (50) when the formation rock closes under overburden pressure once pumping ceases. Alternately, the Attachment Sites (100) can be pumped into the fractures before or after fracture formation, depending on the formation and environmental conditions. The Attachment Sites (100) can be injected into the formation (14) from the surface or from the wellbore without risk of accidental or premature explosion or reaction since the particles don not contain any explosive or reactive materials. The AS (100) particles can be mixed with the proppant (44) prior to being introduced to the treatment fluid (F) or can be added to the treatment fluid before, after or along with the proppant throughout the fracturing process.
The AS (100) particles are preferably approximately the same size as the proppant particles (44) if they are pumped with the proppant. As mentioned above, the AS particles are specially designed such that each AS particle creates a “docking station” that attracts and attaches to only selected Type-1 and Type-2 particles. The AS particle can be a structural particle, such as a sphere, spherical shell, lattice, latticed particle, segmented particle, or other structural particle providing particle-specific attachment sites. Such a “structural particle” has no part in the process of creating a micro-seismic event. That is, the structural AS particle does not itself react or explode. The attachment mechanism can be based on one or more properties of the functionalized layer. Attachment can be based on one or more mechanical, electrical, magnetic, or chemical processes, or a combination of any of these processes. Structural properties, such as shape, material composition, electrical charge, super-paramagnetic behavior, “tentacles,” “sockets,” etc., can be used.
Additionally, more than one “species” of Attachment Site particle (100) can be deployed into fracture space such as AS-x (100-x), AS-y (100-y) and AS-z (100-z) as shown in
The Attachment Sites shown in
An exemplary form of AS particle, seen in
The various surface features described can be created using micro-encapsulation processes and other chemical techniques, as are known in the art, including pan coating, air-suspension coating, centrifugal extrusion, vibration nozzle, spray-drying, ionotropic gelation, coacervation, interfacial polycondensation, interfacial cross-linking, in situ polymerization, matrix polymerization, water beds, etc. One or more shell, membrane or coating layers can be used and the core particles can be hollow, solid, liquid, gel, etc. The shells and layers need not completely surround the core.
Other embodiments of AS particles are seen in
The AS particles are not reactive to create seismic events, thus providing safe transport, handling, mixing, etc., prior to and during deployment. Preferably, the AS particles do not attach to proppant particles, especially if injected into the fracture space after hydraulic treatment. Some layers (104, 134) are shown on
An exemplary shell layer (152), which can be rigid or flexible, provides the support for the outer attachment layer (153) and encapsulates the energetic material of the core (154). In this case, a protective or decay layer is not necessary, as the shell layer (152) provides sufficient stability to reach the attachment site intact. However, such layers may be used. The shell layer (152) can have multiple layers (152a) and (152b).
The T1 particle “payload” of energetic material is contained in the core (154) and is selected to react with a corresponding “payload” of energetic material in a Type-2 particle. Contact or proximity of corresponding Type-1 and Type-2 energetic materials interact to produce a micro-seismic event, such as a detonation, explosion, implosion, exothermic reaction, violent chemical reaction, etc. This process is explained further below. Each Type-1 particle core section carries a “payload” of reactive material for use in creating the micro-seismic event. The concept of payload is familiar to those of skill in the art and can be used to determine the number of Type-1 particles to be injected into the formation, the ratio of Type-1 to Type-2 and AS particles, etc.
When the Type-1 particles are introduced into a fracture network with AS particles present, the shell or attachment layer (153) will attach, mechanically, chemically, etc., to the Attachment Site particles scattered throughout the fracture network. Additional layers or shells can be employed to provide or improve other properties, such as survivability, mobility, flexibility, etc.
The Type-1 particles are preferably of a much smaller size than the proppant or Attachment Site particles. Since the Type-1 particles are preferably introduced into the formation after completion of fracturing, the particles must be able to disperse and move freely in the spaces between the proppant and Attachment Site particles already in place.
As with the Attachment Site particles, multiple species of Type-1 particles can be introduced into the formation fractures. Each species of Type-1 particle, such as Type-1 particle of species-x (150-x), species-y (150-y) and/or species-z (150-z), are selected to attach only to AS particles of the same species. Hence, multiple species of Type-1 particles can be introduced into a fracture and selectively attached to corresponding species of AS particles for the purpose of performing similar surveys at different times.
The protective and decay layers may not be necessary where the layer of the core section provide the structural stability necessary to reach an attachment site, the reactivity to react with corresponding particles upon a triggering event, and the structure, chemistry or characteristic to attach as required.
The Type-2 (160) particles are preferably much smaller than the proppant particles and Attachment Site particles. Since the Type-2 particles are preferably introduced into the formation after completion of fracturing, the particles must be able to disperse and move freely in the spaces defined between the proppant and Attachment Site particles. The Type-1 and Type-2 particles can be of similar or dissimilar size. In a preferred embodiment, the Type-2 particles are smaller than the Type-1 particles, which are, in turn, smaller than the AS particles. While the various particles (proppant, Attachment Site, and Type-1 and Type-2), are shown as spherical for ease of illustration, it is understood that other shapes can be employed with or without the surface features mentioned elsewhere herein, and that the selection of shape may be used to allow, disallow, enhance or reduce attachment of selected particles to one another. Additional layers or shells can be employed, such as decay layers as described elsewhere herein.
As with the Attachment Site and Type-1 particles, multiple species of Type-2 particles can be introduced into the formation fractures. Each species of Type-2 particle, such as Type-2 particles (160-x), (160-y) and (160-z), are selected to attach only to AS particles and/or Type-1 particles of the same species. Hence, multiple species of Type-2 particles can be introduced into a fracture and selectively attach to corresponding species of AS or Type-1 particles.
The insets show a plurality of Type-1 particles of species-x (150-x) attached to an AS particle of the same species (100-x) and a plurality of Type-1 particles of species-y (150-y) attached to an AS particle of the same species (100-y) for the purpose of performing similar surveys at different times.
The reaction (170) caused by the mixing of Type-1 and Type-2 particle payloads may be a chemical exothermic reaction, a low or high order detonation, deflagration, or combustion in a confined environment under elevated pressure and temperature as dictated by the reservoir formation environment and the materials used in the Type-1 and Type-2 payloads. Following the reaction (170), a micro-seismic event (16) occurs which as described elsewhere herein causes waves (18) to radiate from the event site and travel through the subterranean formations. The waves are detected by sensors, such as sensor (21), for example, positioned in the wellbore. Other sensors positioned in monitoring wells (22), the surface (24), or in shallow surface wells (26), also receive the waves, which are detected and recorded as wave data (172) at recording stations (25). Micro-seismic events (16) occur at a plurality of AS particle locations spread across the effective fracture space (50), providing enough micro-seismic events to provide accurate and detailed mapping or surveying of the effective fracture space.
Also seen in
The “time-lapse” mapping concept allows the operator to further manage reservoir production and planning by observing changes over extended periods of reservoir life. For example, a survey using the first species of particles can be performed after a fracturing operation has been completed, but before production has started, to map the propped fractures. A second survey, using another species of particles, may be performed after a selected period (hours, days, months) of production to map the effective fracture space at that time. Another survey can be conducted after a longer production period with yet another species of particles.
The surveys should preferably be performed when the “noise” generated by unrelated events are minimized to improve signal to noise ratio, thereby improving quality and accuracy of the mapping.
Current technology is capable of detecting micro-seismic events which cause pressure changes of as little as tens of psi. Future technology may push that limit of detectability further to lower pressure amplitude pulses. For reference, a measurable micro-seismic event may be equivalent to an event caused by detonation of approximately 1 milligram of common explosive, such as TNT. For comparison, a typical perforation shaped charge is about 10-40 grams of explosives and may cause pressure waves of millions of psi. The goal is to select and operate particle agglomerations which create measureable micro-seismic events from distances (event to sensor) of 30-1500 feet. But the event should also be small enough to meet safety concerns.
The proppant particles are sized by “mesh size” typically. The mesh size of the proppant will generally determine the size of AS and Type-1 or Type-2 particles which can effectively be used. In a preferred embodiment, the AS particles are approximately the same size as the proppant particles. Similarly-sized AS particles can be easily mixed with and dispersed in the proppant. Larger or smaller AS particle sizes may also be used. Particles which are injected or released to the fracture space after the fractures have closed, such as Type-1 and/or Type-2 particles, are preferably considerably smaller than proppant or AS particles so they can effectively flow through the porous space formed by the trapped proppant particles in the fracture space. As an example, a typical Type-1 and/or Type-2 particle may be between 1/14th and 1/318th the size of an AS or proppant particle. Such a size allows the particles to flow through the proppant and allows multiple particles to attach to one or more AS particles. These approximate figures are based on spherical geometries; therefore other sizes may be desirable to accommodate non-spherical particle geometry.
The concept of Attachment Sites allows the micro-seismic event density, that is, the number of micro-seismic events generated (and measured) per unit volume of fracture space, to be selected during the design phase of the survey. Similarly, the ratios and amounts of the Type-1 and/or Type-2 particles can be selected based on payload, attachment mechanism, volume of disbursement, density of AS particles, etc. for each individual survey depending on the reservoir properties, environmental conditions and a number of other variables As an example, for a micro-seismic survey where 1 mm size proppant and the same size AS particles are used, if the desired survey of micro-seismic events is about one per square meter of fracture space, then the required AS concentration would be approximately 1 AS particle per 1 million proppant particle for every mm of fracture width. Hence, if the estimated eventual fracture width is calculated to be approximately 3 mm, then the AS to proppant ratio should be targeted at about 3-5 AS particles per 1 million proppant particles, allowing for non-uniform distribution and other losses. In practice this results in a very workable amount of AS particles for such a survey. Assuming similar bulk densities for proppant and AS particles, the above example requires 3-5 pounds of AS particles per million pounds of proppant. Preferably a much higher number of Type-1 and/or Type-2 particles are injected to insure sufficient numbers reach and attach to the AS particles, provide sufficient payload at any given attachment site to ensure a measurable micro-seismic event, etc.
Triggering events cause initiation of the micro-seismic events. In a preferred embodiment, after the AS, Type-1 and/or Type-2 particles are in position, dispersed at locations throughout the fracture space, the reactive particles are triggered by a triggering event to initiate micro-seismic events at each location. The triggering event can include multiple stages, such as a decay stage for removing decay layers from the particles. The decay stage can, for example, include methods such as injecting a fluid (brine, acid, chemical wash, etc.) into the formation to dissolve or otherwise remove any decay layers. Alternately, the decay stage can employ a change in an environmental condition such as temperature, pressure, salinity, pH, etc. For example, high salinity water can be injected to dissolve one or more decay layers on one or more particles, thereby triggering a reaction between the now-exposed core sections of the Type-1 and Type-2 particles. Alternately, the triggering event can simply be a time delay during which the protective shells dissipate and/or coalesce allowing the reactive payloads to come into contact and/or to mix with each other thereby initiating a reaction.
The core sections of the Type-1 and Type-2 particles carry payloads of explosive or reactive material (or initiating, catalytic materials, etc.) which, upon contact with the other core section material(s), cause the explosion, reaction, etc.
Where multiple species of AS, Type-1 and Type-2 particles are employed, various triggering events may be selected to start successive series of micro-seismic events for each species type. It is also possible to release Type-2 particles which simply react immediately upon contact with the Type-1 particles. The micro-seismic events would then occur as the Type-2 particles are injected and progress through the fracture space and become attached to type-1 particles of the same species.
Advancements over prior art included in the inventive methods are injection or introduction of the reactive particles after conclusion of fracturing and/or without mixing of the particles at the surface or in the wellbore above the formation. Further, the reactive or energetic particles are not then prone to accumulating in unwanted areas, such as in a mixer, at the surface, along the wellbore, etc.
Other release mechanisms may be employed. For example, the AS particles may also be injected or pumped into the formation using a downhole tool after completion of fracturing processes. However, this would necessitate the use of AS particles of much smaller size, to flow through the proppant particles, which would compromise their effectiveness as attachment sites, especially where designed to attract and attach to multiple reactive particles.
All or part of the surveying (500) and data processing (600) stages may be repeated at a later time using additional species (T1-z and T2-z), to provide a second fracture mapping survey, allowing a “time-lapse” capability.
Additional methods are presented for producing a plurality of micro-seismic events in a fractured formation. The following methods described are derived from the previously described method and details will not be repeated. Details of the primary method are applicable to the following methods, with exceptions and differences indicated below.
Another preferred method does not employ Attachment Site particles. In other words, no AS particles are positioned within the effective fracture space. Type-1 particles are injected or introduced into the propped fracture space after fracturing has ceased. Multiple species of Type-1 particle may be introduced. The Type-1 particles may have the structures (core, layers, etc.) and chemistry as discussed elsewhere herein. Preferably the Type-1 particles have a reactive material core section and an attachment layer for attaching Type-2 particles.
After dispersal of the Type-1 particles within the propped fracture space, a first species of Type-2 particles are introduced into the fracture space. Type-2 particles preferably have a core section specifically designed or selected to initiate a reaction with corresponding Type-1 particle cores. One or more layers of the Type-2 particles facilitate attachment to the Type-1 particles.
Multiple species of Type-2 particles may be used for multiple surveys as described above. The various species can be introduced to the fracture network simultaneously and triggered by separate triggering events, or can be introduced sequentially after triggering of previously introduced species.
In another embodiment, Attachment Site particles and Type-1 particles are incorporated. These particles can be described as “modified” Type-1 particles that have many of the characteristics of the above-described AS particles. For example, the modified T1 particles can be larger, stronger, or use attachment features such as latticework, ports, etc. In this method, modified Type-1 particles are mixed with proppant and pumped into the fracture space. When pumping ceases, the particles are entrapped within the fracture network. The modified Type-1 particles are exposed to high pressures and fracture fluid chemistry during pumping and entrapment and it is expected that many of them may not survive. This disadvantage may be compensated for by increasing the concentration of modified Type-1 particles within the proppant. Multiple species of modified Type-1 particle may be introduced. It should be noted that the payload of the modified Type-1 particle does not present a hazard during the pumping stage as it contains only one of the components required for the energetic reaction. After a suitable period of time has passed to allow for optional clean-up, etc., the first species of Type-2 particles are introduced into the fracture network. Type-2 particles preferably have cores of specifically designed or selected materials that initiate reactions with corresponding Type-1 particles. One or more layers of the Type-2 particles facilitate attachment to the Type-1 particles. Multiple species of Type-2 particles may be used for multiple surveys as described above. Multiple species may be introduced to the fracture network simultaneously or sequentially and react upon separate triggering events.
According to an exemplary method, Attachment Sites (AS) of several species are pumped with the fracturing fluid into the fracture network and entrapped. As described herein, the AS particles are suitable proppant size particles that have specially designed outer shells such that each AS creates a “docking station” that attracts and accepts only a specific “species” of Type-3 particles. Type-3 particles are then introduced into the fracture space. Type-3 particles (200) have an inner core section (204) which carries a payload of selected materials that react with the payload materials contained in outer core (210). A separation layer or capsule (206) separates the inner and outer core sections. The partition (206) can be triggered to allow contact between the payloads, such as by means of changes in environmental conditions (e.g., temperature, pressure, etc.) or by time decay, etc., as discussed above. The partition (206) can be a membrane, coating, layer or multiple such mechanisms. An outer shell (220) consists of one or more layers of selected materials to isolate the outer core materials from the environment until an appropriate triggering event. The selectivity of Type-3 particles based on the “species” concept described above can apply as well.
Attachment sites (docking stations), Type-1, Type-2 and Type-3 particles can be of any suitable size and shape to fit the fracture space and to contain required amounts of materials.
The outer layer (shell, capsule or coating) design of the Attachment Sites, Type-1, Type-2 and Type-3 particles determine the unique species of the particles in such a way that only the same species of components attach to each other. By this concept of distinct and separate species of particles, it is possible that the system may be operated selectively, as and when needed, by later introducing or triggering different species of particles (assuming this species of the Attachment Sites were entrapped within the fracture space).
The outer layer section of Type-1, Type-2 and Type-3 particles can be sufficiently elastic to enable the particles to deform without structural damage to pass through restrictions.
The preferred methods, where only the Attachment Sites are pumped with the proppant during the fracturing process, have distinct advantages, such as preventing premature exposure of the energetic payloads to harsh conditions or chemicals present in treatment fluids.
The methods are capable of selectively activating varying amplitude (strength) seismic events at controlled times by using the delivery devices and methods explained herein.
The release mechanism design for T1, T2, and T3 particles allows selective surveys within fracture networks created by multi-stage hydraulic stimulation jobs.
The system allows “Time-lapse” surveys to be performed as and when required.
The particle shells, layers or coatings are preferably made of one or more of the following chemicals in the following Groups, alone or in combination, and may be cross-linked at any percentage by any number of means known in the art, in single or multiple layers over a particle core section or sections. Exemplary shell, capsule or coating materials include:
The particle core sections of energetic or reactive materials, are made of one or more of the following chemicals, alone or in combination, and may be combined at any percentage by any number of means known in the art, in any total weight to achieve a sufficient specific energy to generate the required micro-seismic event strength. Exemplary core and payload materials include:
An exemplary coating (346) can be rigid or flexible, can fully or partially cover the proppant particle (348), can be fully or partially depleted upon reaction with reactive particles (362), and can be used in conjunction with the various protective or delay coatings and layers discussed elsewhere herein. In the preferred embodiment, no protective or decay layer is necessary, as the coating provides sufficient physical stability to reach the fractures intact.
The coating is designed to react with reactive particles (362), producing micro-seismic events. The reactive particles (362) are preferably smaller than the un-treated proppant particles (344) and treated proppant particles (370). The reactive particles (362) are shown as solid or semi-solid masses in the figures, however, it is to be understood that this is merely a representation and is not limiting as to the form, substance, properties, materials, or state of matter of the reactive particles. For example, the reactive particles (362) can be solids suspended in fracturing fluid, gel, etc., dissolved chemical compounds in the fracturing fluid, placed in treatment fluids ahead of or behind the primary treatment.
Generally, the coating of the treated proppant chemically reacts with reactive particles (362). The coating (346) of the treated proppant can be said to carry a “payload” of energetic material and is selected to react with a corresponding “payload” of energetic material in one or more reactive particles. Contact of corresponding energetic materials cause an interaction producing a micro-seismic event, such as a detonation, explosion, implosion, exothermic reaction, violent chemical reaction, etc. The concept of “payload” is familiar to those of skill in the art and can be used to determine the number, weight, volume, or other measure of coating, treated proppant, untreated proppant, and reactive particles to be injected into the formation, and the relative ratios thereof. The reactive particles are preferably much smaller than the proppant and coated proppant to enhance their ability to disperse and move freely in the spaces between the proppant particles.
The coating can be applied to the proppant particle by any known methods, including micro-encapsulation, pan coating, air-suspension coating, centrifugal extrusion, vibration nozzle, spray-drying, ionotropic gelation, coacervation, interfacial polycondensation, interfacial cross-linking, in situ polymerization, water beds, etc.
The treated and untreated proppant particles (344) and (370) can be mixed at the surface, during insertion into the wellbore, at a downhole location within the wellbore, or in the formation. Where the reactive particles and treated proppant is mixed or otherwise combined at the surface or during injection, it is expected that reactions may well occur prior to injection into the formation fractures. In such a case, the reactions are designed to produce micro-seismic events at such a small scale that no damage is done to the well, wellbore, tools. Similarly, the reactions must be controlled to protect personnel. Where the treated proppant (370) includes additional layers, coatings, materials, etc., to delay any reaction, there may still be some reactions which occur prior to injection into the formation. In such instances, the reactions are designed to be of such small magnitude as to not cause harm. Alternately, these issues can be mitigated or avoided by introducing the reactive particles to the wellbore or formation generally after injection of the proppant particles.
In a preferred embodiment, the coating (346) can be designed to “crack,” thereby exposing the coating to potential reaction, under the increased pressure on the particles caused when the fractures “relax” or close upon cessation of pumping of fracturing fluids, or when the fracturing gel, slurry, etc., liquefies or disperses. In another embodiment, the micro-seismic events can occur upon precipitation of reactive particles from the fracturing fluid.
In other embodiments, catalysts and/or inhibitors can be used in conjunction with the reactive particles to control timing of the reactions. Such catalysts and inhibitors can be present in the fracturing fluid, later-added, or injected prior to injection of the reactive particles. Such catalysts and inhibitors could be the product of a secondary chemical reaction that occurs within the fracturing fluid. The reactions of the coating of the treated proppant and the reactive particles is similar to that described elsewhere in this specification and will not be repeated here.
For the embodiments and methods described wherein a reactive coating of a treated proppant particle interacts to create a micro-seismic event with one or more reactive particles, the materials listed in the following Groups, alone or in combination, in single or multiple layers, in combination with binding or other materials, in various phases, mixtures, suspensions, etc. can be used, or are expected to operate, as reactive coating materials and/or reactive particle materials:
Another embodiment and method are presented with respect to
Proppant particles (444) are pumped into the fractures along with the fracturing fluid. The non-reactive proppant particles (444) can be any type of proppant particle known, or which may become known, in the art and will not be discussed in detail herein. After pumping of the fluid (F) ceases, the fracture closes or seals to an effective fracture (450), indicated graphically in cross-sections (452). A typical fracture has a much greater length (455) than width (453) and can vary in height (454). These dimensions may become critical parameters for selecting size and amounts of proppant, particles and fluid injected into the formation, design of a fracturing plan, etc.
Also seen in
The coated reactive particles (445) have one or more coatings (446). The coatings encapsulate, preferably completely, the core section and prevent premature reaction. The coating is selected to delay or control timing of the interaction between the core reactive material and the triggering particles. The coating is removable, such as by dissolution, reaction, decomposition, dissipation, melting, chemical stimulus including pH and salinity, etc., in response to the effect of one or more triggering particles.
The removal particles (480) can be injected in a carrier fluid, such as water, brine, diesel, or fracturing fluid, and can act to remove the coating only in the presence of a catalyst, if desired. The carrier fluid can also be used to inject catalyst particles (462) into the formation. The carrier fluid can transport one or both of the removal and triggering particles.
In a preferred embodiment, a single type of selected particle can perform both the functions of removal of the coating on the reactive particle and triggering of the reactive particle. That is, a single fluid or material both removes the coating and reacts with the reactive material of the reactive particle. In another embodiment, a carrier fluid, such as brine, removes the coating while a dissolved or suspended material in the brine triggers the reaction. The reaction of reactive particles and catalyst particles is similar to that described elsewhere in this specification. Further, the use of catalysts, inhibitors, etc., is discussed elsewhere herein and not repeated here.
Delivery, mixing, and types of fracturing, treatment, and well fluids are well known in the art and will not be discussed in detail herein. The proppant (444), coated reactive particles (445), removal particles (480), and catalyst particles (462) can be delivered to the formation by known means.
The materials available for use as removable (non-reactive) coatings, removal particles, reactive materials, catalyst materials, etc., are discussed and listed elsewhere herein and will not be repeated here in the interest of brevity. Those of skill in the art will recognize those materials which are appropriate for use in the various embodiments described immediately above. The reactive materials listed above can be used in or to create the reactive core and/or reactive particles. Potential removable coating materials, and removal particles and methods are discussed above herein.
Another embodiment and method are presented with respect to
As further shown in
As previously noted proppant particles are typically sized by “mesh size”. The mesh size of the proppant will generally determine the size of acoustic particles (490) that can effectively be used. In a preferred embodiment the acoustic particles (490) are slightly larger (i.e., have a longer diameter on average) than proppant particles (484), although acoustic particles (490) having a similar size or that are smaller (i.e., have a shorter diameter on average) than proppant particles (484) may also be used, depending upon the specific application and environment. In most embodiments the sizes would range from 100 to 4 mesh.
The core (491) can be any material that is sufficiently rigid to permit application of compressive force to the trigger particles sufficient to generate an electrical charge. The choice of material is dependent on the desired density and/or electrical conductance. The core may comprise nonconductive or conductive material, and may be hollow or solid. For instance, if a higher density is desired then a solid core may be preferred. As used herein, “nonconductive” and “minimally conductive” are defined as having a a-value (S/m) of less than 1 at 20° C. Any material having a a-value (S/m) of 1 or greater at 20° C. is considered “conductive”, for example, a metal, which would be well suited for applications of the acoustic particle requiring a higher density.
The core (491) may be covered with a conductive layer (495). A conductive layer may be particularly advantageous depending upon the particular application and the desired density and/or electrical conductance. A conductive layer is particularly desirable where the core is, or is substantially, comprised of minimally conductive materials. One such material is a glass composed of at least 75% SiO2. The core (491) may be partially or entirely covered with a conductive layer (495). In this embodiment the reactive material is positioned between the conductive layer and the outer layer. Suitable materials for the conductive layer include but are not limited to carbon materials, and particularly those that are ordered and/or have a repeating network having a high conductance, for example, graphene or a material having similar qualities. Other suitable materials include various metals such as silver, copper, gold, and platinum, and such materials may be applied by any means known to one of skill in the art. A core comprising a conductive material may include a conductive layer, although it is contemplated that a core comprising a conductive material is not covered with a conductive layer.
In another embodiment as shown in
Trigger particles (494) comprise any material or electromechanical system that reacts to a compressive force to generate an electrical charge capable of initiating or accelerating a reaction of the reactive material(s). Such materials include, but are not limited to, natural and synthetic materials, and include crystals, ceramics, polymers, minerals, and derivatives thereof. Suitable crystals include crystals derived from boron silicates or compounds comprising boron silicates, gallium phosphates and Langasite, crystalline calcium phosphate, synthetic ceramics with perovskite or tungsten-bronze structures such as barium titanate, lead titanate, lead zirconate titanate (PZT), potassium niobate, lithium niobate, lithium tantalite, sodium tungstate, and zinc oxide. Lead-free piezoceramics are also desirable and include but are not limited to sodium potassium niobate, bismuth ferrite, sodium niobate, bismuth titanate, and sodium bismuth titanate. Suitable polymers may also be used, such as, for example, polyvinylidene difluoride (PVDF), that may depend on the specific application and temperature and pressure conditions. Additional suitable materials include diphenylalanine peptide nanotubes (PNTs) and fossilized tree resins (amber) and the like. The average diameter of the trigger particles suitable for use is 0.5 to 3 millimeters and preferably 1 to 2 millimeters.
The ratio in the size of the trigger particle relative to the acoustic particle may vary depending on the application and environment. In most embodiments the ratio of the average mesh size of the trigger particle (494) to the average mesh size of the acoustic particle (490) ranges from 1:2 to 1:100, 1:2 to 1:15, 1:2 to 1:10, and 1:2 to 1:5. In the embodiment of the acoustic particle lacking a core (e.g., as illustrated in
The reactive material (492) may comprise one or more of the energetic or reactive materials described previously, alone or in combination, and may be combined at any percentage by any number of means known in the art, in any total weight to achieve a sufficient specific energy to generate the required micro-seismic event strength. It is generally believed that the dielectric constant of the reactive material should be less than the other components and in particular the trigger particles.
Outer layer (493) is insulating and/or protective for the electrical charge produced by the trigger particles (494). The outer layer is preferably resilient such that it will yield upon subjection to compressive forces exerted during fracturing or upon closing of the fracture. The layer can be collapsible as long as sufficient force is exerted upon the trigger particles (494) to generate an electrical charge that leads to a detectable seismic pulse. Outer layer (493) is preferably made of one or more of the coating materials described previously, alone or in combination, and may be cross-linked at any percentage by any number of means known in the art, in single or multiple layers. Water-insoluble polymers are especially well-suited, and synthetic polymers such as polyethylene, polypropylene and polytetrafluoroethylene are particularly preferred.
Acoustic particle (490) may include a second outer layer (496), as shown in
Coating materials for the second outer layer (496) or for inclusion in outer layer (493) that may be suitable for reducing the acoustic particles' (490) coefficient of friction include fatty amides, fatty acids, fatty esters and metallic fatty acids and more advantageously include fatty amides, fatty acids, fatty esters, and metallic fatty acids having from about 10 to about 28 carbon atoms preferably from about 10 to about 22 carbon atoms and include, but are not limited to, stearyl stearamide, erucamide, oleamide, oleyl palmitamide, stearamide, behenamide, ethylene bisstearamide, ethylene bisoleamide, stearyl erucamide, myristic acid, palmitic acid, palmitoleic acid, erucyl stearamide, capric acid, lauric acid, stearic acid, oleic acid, vaccenic acid, linoleic acid, linolenic acid, eleostearic acid, arachidic acid, arachidonic acid, behenic acid, lignoceric acid, nervonic acid, cerotic acid, montanic acid, caprate, laurate, myristate, palmitate, palmitoleate, stearate, oleate, vaccinate, linoleate, linolenate, eleostearate, arachidate, arachidonate, behenate, lignocerate, nervonate, cerotate, montanate, pentaerythritol monopalmitate, pentaerythritol monostearate, pentaerythritol dipalmitate, pentaerythritol palmitate stearate, pentaerythritol distearate, and the like. Advantageous hydrocarbon oils include, but are not limited to, mineral oil, silicone oil, and the like. Lubricating materials suitable for the present invention further include plasticizers, dibasic esters, silicones, anti-static amines, organic amines, ethanolamides, mono- and di-glyceride fatty amines, ethoxylated fatty amines, fatty acids, zinc stearate, stearic acids, palmitic acids, calcium stearate, lead stearate, sulfates such as zinc sulfate, etc., and the like. The above lubricating materials may be used individually or in combination.
Suitable dispersants for inclusion in the second outer layer (496) or for inclusion in outer layer (493) include sodium cetyl sulfate, ammonium lauryl sulfonate, ammonium di-isopropyl naphthalene sulfonate, sodium oleyl glyceryl sulfate, mahogany and green sulfonates from petroleum or petroleum fractions or extracts, sodium stearamido-ethyl sulfonate, dioctyl sodium sulfosuccinate, sodium naphthenate, cetyl pyridinium chloride, stearamidoethyl pyridinium chloride, trimethyl heptadecyl ammonium chloride, dimethyl-pentadecyl sulfonium bromide, octadecylamine acetate, 2-heptadecyl 3-diethylene diamino imidazoline diacetate, and similar surfactants suitable as an optional coating under the applicable circumstances.
Delivery, mixing, and types of fracturing, treatment, and well fluids are well known in the art and will not be discussed in detail herein. Proppant (484), acoustic particles (490) having core (491), reactive material (492), and trigger particle (494) covered by an outer layer (493), optional core conductive layer (495) and optionally a second outer layer (496) can be delivered to the formation by known means.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2013/055799 | 8/20/2013 | WO | 00 |
