Not applicable.
The present disclosure relates generally to tools used to pierce well casing to allow fluids to pass into and out of a wellbore annulus.
Currently, there are a number of solutions for well piercing tools. These typically use shaped explosive charges to pierce a well bore casing. The piercing shaped charges and ancillary components are contained within a sealed unit. Some of these solutions attempt to connect each individual unit together with threaded connections, but these solutions fail to meet the needs of the industry because the threaded connection between each unit adds length, material, cost and complexity. Typically, this has been done with a box by box barrel with a pin by pin sub between each unit. Other solutions attempt to eliminate the sub by creating a box by pin barrel, but these solutions are similarly unable to meet the needs of the industry because there is still a threaded connection between each unit adding to the length and cost. Still, other solutions seek to put shaped charges in a planer configuration to shorten the units, but these solutions also fail to meet industry needs because they significantly decrease the shape charge size sacrificing pierce depth and performance for a shorter assembly. Manufacturing costs with all of the existing systems remain high due to complexity and material costs.
The present disclosure relates to a device and a method associated with tools designed to pierce casing for the oil, gas, geothermal and water wells. With respect to the device, it is a multiple chambered piercing assembly, which separates piercing units without threaded connections between each unit, allowing for a lower cost, more compact design compared to current tube piercing systems on the market today. Due to the reduced length this device can be used to increase the number of chambers put into a single tool string for piercing the casing in more spread out locations along a well zone, thereby allowing a more evenly distributed fluid outflow or inflow from the formation while maintaining limited hole entry through the casing.
The core components of the invention are an external tube, short segmented internal tubes, and divider pucks on each end of the shorter tube segments. The pucks will include of an electrical pass through pressure barrier and will contain a thinner internal tube (carrier tube), shape charge, and a detonator. The carrier tube will hold and align a shape charge and detonation system with the outer sleeve. Generally speaking, one set of units of this system will be configured as follows: the outer sleeve will be threaded and cap on both ends with electrical feed through. Multiple units will be inserted into the outer sleeve with sealed chambers in between each unit. A unit will include an inner sleeve with a divider puck on each side. The divider puck will seal on the inner diameter (“ID”) of each inner sleeve as well as provide a bore to pass an insulated electrical signal through that will double as a pressure barrier. Between the pucks inside each inner sleeve section is a pressure sealed chamber with one or more shape charges that will reside with an explosive initiation system. The explosive initiation system in one form may include a detonator, detonation cord, and an addressable switch.
With respect to the device, it should be further noted that any number of units can be placed inside the outer sleeve depending on the job requirements and only limited by physical constraints from other systems. With respect to the associated method, in order to carry out the method the following core steps are followed: the outer sleeve will be capped off on one side. All of the units will be assembled one by one and placed inside of the outer sleeve. Once the outer sleeve is completely filled with units, the open side of the outer sleeve will be capped. The capped ends of the outer sleeve will have an electrical pass through that can either be tied to another outer sleeve assembly or a different tool in a wireline tool string. For example, a setting tool on the bottom (side B) and a cable head at the top (side A). “Top” is in reference to the last portion of the assembly that will enter the well bore when traversing from the surface into the ground while “bottom” is the first portion of the assembly that will enter. The assembly will then be drawn into a pressure chamber using a high tension cable. The pressure chamber is then placed onto the well head and then the pressures equalized between the chamber and the well bore. The assembly is then pumped down into the well where piercings are desired in the casing to allow fluids to flow into and out of the casing. The bottom most unit in the outer sleeve will be initiated first, setting off all of the shape charges within the unit's chamber. Each unit above the previous will be initiated in order until all of the units are detonated. The assembly will then be pulled to the surface and the pierced zone of the well may be hydraulically fractured. Ultimately, at the conclusion of these steps an advanced multiple unit piercing assembly will be assembled and used in the well to put holes in the casing enabling fluid to enter or exit the annulus of the well.
The term “at least one”, “one or more”, and “one or a plurality” mean one thing or more than one thing with no limit on the exact number; these three terms may be used interchangeably within this disclosure. For example, at least one device means one or more devices or one device and a plurality of devices.
The term “about” means that a value of a given quantity is within ±20% of the stated value. In other embodiments, the value is within ±15% of the stated value. In other embodiments, the value is within ±10% of the stated value. In other embodiments, the value is within ±7.5% of the stated value. In other embodiments, the value is within ±5% of the stated value. In other embodiments, the value is within ±2.5% of the stated value. In other embodiments, the value is within ±1% of the stated value.
The term “substantially” or “essentially” means that a value of a given quantity is within ±10% of the stated value. In other embodiments, the value is within ±7.5% of the stated value. In other embodiments, the value is within ±5% of the stated value. In other embodiments, the value is within ±2.5% of the stated value. In other embodiments, the value is within ±1% of the stated value. In other embodiments, the value is within ±0.5% of the stated value. In other embodiments, the value is within ±0.1% of the stated value.
Terms and phrases used in this disclosure, and variations thereof, unless otherwise expressly stated, should be construed as open-ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like, the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof, the terms “a” or “an” should be read as meaning “at least one,” “one or more,” “one or a plurality” or the like.
As described herein, it is desirable to provide a device that has the shortest unit length possible and a low manufacturing cost. Furthermore, it is desirable to not require twisting of components relative to each other while assembling the components at risk of damaging wires. Also, it is desirable to have a system that can orient the charges along its axis simply by pushing them together with a simple orienting mechanism. Therefore, there currently exists a need in the industry for a device that eliminates the majority of the threaded connections between most units. Similarly, it is desirable to have an associated method that eliminates orienting mechanisms that are challenging to implement or that add significant length to the system. Therefore, there currently exists a need in the industry for a process that assembles multiple units of shorter length into a single long outer sleeve as described here.
Disclosed herein is a multiple unit piercing assembly, which is made up of the following components: (1) an outer sleeve; (2) segmented internal tubes; (3) puck dividers that encapsulate a shape charge(s); and, in one embodiment, (4) an explosive initiation system. These components are assembled into a single unit with multiple units (sub-assemblies) contained within the outer sleeve. This is done as follows: an outer sleeve is used to encapsulate all of the internal components. Caps are mechanically attached to both sides of the outer sleeve to restrain all of the components in tension as explosives in each unit are initiated. The outer sleeve can, but does not need to be sealed off from wellbore pressure. A set of inner sleeves with pucks between and on both sides are placed inside of the outer sleeve. The pucks interface with the outer sleeve as well as the inner sleeve. The puck's interface would ideally seal on the outer sleeve end caps as well as the inner sleeves forming a pressure sealed unit comprising an inner sleeve between two pucks. Each inner sleeve will encapsulate a shape charge(s) as well as an explosive initiation assembly in one of the embodiments. The pucks will also have at least one electrical pass through that enables a signal to be passed into the chamber to initiate the explosives. Similarly, multiple unit piercing assembly comprises the following steps: affixing a cap to the outer sleeve, assembly and insertion of each unit sub assembly until the outer sleeve is full, affixing a cap to the open end of the outer sleeve, attachment of the cable both electrically and mechanically to the multiple unit piercing assembly(s), running the multiple unit piercing assembly into the well and initiating each unit individually starting at the bottom and working to the top until all units are spent. At which point the assembly is brought to the surface for disposal. The well can now pass fluid into or out of the casing annulus.
The device of this disclosure may also have one or more of the following: (1) ported or scalloped outer sleeve to minimize the protrusion of burrs past the major outside diameter after shape charges are initiated and pierce the inner sleeve, (2) multiple electrical pass through pressure barriers on a puck to allow additional signals or detonator initiation voltage to be passed through upper units without charge initiation, (3) oriented shape charges that align the shape charges between each unit as well as to features of the outer sleeve, (4) one of more shape charges per unit allowing one or more holes to be pierced in the casing with the initiation of a single unit. (5) Sealing between units could be done between the major outside diameter of the pucks and the inside diameter of the outer tube or sealing on the inner sleeve as well as the pucks. Similarly, the associated method may also include one or more of the following steps: assembly of an addressable switch head at the top or bottom of the multiple unit piercing assembly. This would add the additional step of isolating and connecting multiple lead pressure barriers into the puck between units during assembly. (6) A puck could be attached to each end of each inner sleeve, yielding two pucks per unit. These pucks could have mating, sealing surfaces between each unit. (7) Pucks could be designed with multi-lead threads to lock the inner sleeves onto the puck without excessive rotation of the components relative to each other. (8) A puck and inner sleeve could be integrated into a single part into a box-by-pin type attachment, further reducing the number of components in a unit. (9) The outer sleeve and one end cap could similarly be made as a single, integral component for box-by-pin style assembly of the outer sleeve/end caps.
The disclosed device is unique when compared with other known devices and solutions because it provides: (1) multiple unit assemblies without the need for threaded connections between them; (2) short unit length; (3) easy orientation of units relative to each other; and (4) a modular design that enables easy adaptation to customers' needs. Similarly, the associated method is unique in that it (1) decreases the length of pressure chamber needed for a given number of units and subsequently the crane height required to insert the tools into the well; (2) creates easier assembly between units because they do not need to be rotated during assembly (no twisted wires or damaged O-rings) and lighter components due to smaller size; and (3) the unit stack can be removed as a set, armed and reinstalled with the outer tube being the only part requiring mechanical attachment of end caps to withstand high tensile loading.
The disclosed device is unique in that it is structurally different from other known devices or solutions. More specifically, the device is unique due to the presence of (1) multiple units that can individually be addressed and initiated at different locations in the well bore while maintaining a very short assembly length; (2) no tensile carrying mechanical connections such as threads are needed between each unit within a multiple unit piercing assembly; and (3) the outer sleeve and end caps are the only component that needs to carry tension along its axis while traversing the well or during initiation of shape charges.
Furthermore, the process associated with the aforementioned device is likewise unique. More specifically, the disclosed process owes its uniqueness to the fact that it (1) multiple units can be removed from the outer tubing assembly and armed as an assembly without fully disassembling each unit; (2) sets of units can be easily shipped without thread protectors fully assembled into a multiple unit piercing assembly because of the minimal effort required to disassemble them for addition of a detonator; and (3) during assembly of more than one multiple unit piercing assembly the different units are easier to handle because of their modular nature and smaller size. This method of handling multiple units in a modular form makes operations in the assembly shop and in the field more efficient.
This disclosure will now provide a more detailed and specific description that will refer to the accompanying drawings. The drawings and specific descriptions of the drawings, as well as any specific or alternative embodiments discussed, are intended to be read in conjunction with the entirety of this disclosure. The Multiple Unit Piercing Assembly may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and fully convey understanding to those skilled in the art.
The invention relates generally to tools used to pierce well casing to allow fluids to pass into and out of a wellbore annulus.
In its most complete form, the device is made up of the following components: the outer sleeve includes open ends on both sides. Both sides of the outer sleeve will have features such as threads or engagement holes to allow mechanical attachment of the side A and B end caps to enclose a volume in between. Both end caps will have at least one hole to allow a pressure sealed electrical pass through devices to be inserted. The end caps can have a pressure seal to the inside of the outer sleeve, but in its most ideal form will have a pressure seal between the end cap and an internal puck or the first and last inner sleeve of the unit stack. If the outer sleeve has scallops or holes cut on it, the ID of the outer sleeve may have a feature for orientation of the internal components to the outer sleeve features. This could be as simple as a slot cut through the tube or an internal keyway cut on the inside diameter of the outer sleeve. The puck on one side will be mechanically attached to the charge carrier tube. One way to attach the charge carrier tube to the puck is by a small screw that passes through a hole in the side of the charge carrier tube and threads into a hole on the circumference of the puck.
A shape charge will be inserted into the side of the charge carrier tube with the two components axis' perpendicular with respect to each other. A detonator will be held against the back of the shape charge in a single shape charge configuration. If multiple shape charges are required, a detonation cord will be wrapped around the back of each shape charge with a detonator held against the side or end of the detonation cord. In the simplest form of the multiple unit piercing assembly, an addressable switch will be placed inside of the charge carrier tube. The wiring of the switch will be performed just outside of each unit chamber before the wires are pushed inside the chamber and it is sealed off on either side with a puck. The input and output communication wires from the addressable switch will be connected to the electrical pass through on puck A and puck B respectively. The internal switch would have two leads connected to the detonator wires and the final lead grounded to the puck, carrier tube, or inner sleeve. The explosive assembly includes the shape charge, detonator, detonation cord (if multiple shape charges are used or if necessary), the charge carrier tube, and an addressable switch (if a switch head assembly is not used). This sub assembly will be mechanically attached and aligned with the first puck and the first side of the inner sleeve will be slid over the entire assembly with the puck sealed to the inner sleeve. The other side of the inner sleeve will also have a puck installed sealing off the second side as well. The carrier tube will also be held concentric with the inner sleeves between the pucks but could be offset if needed. The carrier tube could have mechanical timing between puck A and puck B on side A and side B of the unit. Timing between the charge and the outer sleeve could also be accomplished by timing the carrier tube to the puck and the puck to the outer sleeve after fully assembled. A stack of units will be built to the appropriate length before being inserted into the outer sleeve. Puck A and puck B may require unique geometry to seal to either end cap on the outer sleeve. The stack of units will have a puck on either side with one puck between each inner sleeve creating multiple pressure sealed chambers for each unit. In an alternative embodiment, the inner sleeves on each end of the multiple unit stack could seal directly to the end caps. The stack of units will be inserted into the outer sleeve and captured between the end caps on either side of the outer sleeve. Electrical signal wire will have continuity from the outer sleeve end cap through the unit stack to the end cap on the opposite side of the outer sleeve end cap. The multiple unit piercing assembly can then be mechanically and electrically connected to additional multiple unit piercing assemblies or other wire line tools such as plug setting tools, CCL, release tools or a cable head.
A single shot selection in the present system may be as short as 20.32 cm (8.0 inches) with 5.08 cm (2.0 inches) added for every additional shot. For example, a dual shot may be 25.4 cm (10.0 inches) and a triple shot may be 30.48 cm (12.0 inches). As a comparison, a conventional perforating gun is at least 25.4 cm (10.0 inches) in length per selection.
Suitably, the diameter of the outer sleeve 400 may be dictated by the well bore dimensions and conditions. A standard gun diameter has a diameter of 7.94 cm (3.125 inches). In one embodiment, the outer sleeve 400 may have a minimum wall thickness of 0.32 cm (0.125 inches) and a maximum wall thickness of 0.95 cm (0.375 inches). The inner sleeve 100 will always have a slight smaller outer diameter (“OD”) (clearance fit) to the ID of the outer sleeve 400. The inner tube for a 3⅛″ gun system may have a maximum outer diameter of 7.3 cm (2.87 inches) with a minimum wall thickness of 0.16 cm (0.0625 inches) and a maximum wall thickness of 0.95 cm (0.375 inches). Wall thickness is dictated by service conditions. In addition, a thin wall inner sleeve 100 may be supported by rings inside the tube used to prevent buckling.
Different features, variations and multiple different embodiments have been shown and described with various details. What has been described in this application at times in terms of specific embodiments is done for illustrative purposes only and without the intent to limit or suggest that what has been conceived is only one particular embodiment or specific embodiments. It is to be understood that this disclosure is not limited to any single specific embodiments or enumerated variations. Many modifications, variations and other embodiments will come to mind of those skilled in the art, and which are intended to be and are in fact covered by this disclosure. It is indeed intended that the scope of this disclosure should be determined by a proper legal interpretation and construction of the disclosure, including equivalents, as understood by those of skill in the art relying upon the complete disclosure present at the time of filing. The embodiment(s) described herein are meant to be illustrative only and should not be taken as limiting the invention, which is defined in the claims.
All original claims submitted with this specification are incorporated by reference in their entirety as if fully set forth herein.
This application claims benefit of U.S. Provisional Patent Application Ser. No. 63/156,535, filed on Mar. 4, 2021, the content of which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63156535 | Mar 2021 | US |