Patent Grant
11965719
After drilling a wellbore in a subterranean formation for recovering hydrocarbons such as oil and gas lying beneath the surface, a casing string may be fed into the wellbore. Generally, the casing string protects the wellbore from failure (e.g., collapse, erosion) and provides a fluid path for hydrocarbons during production. Traditionally the casing string is cemented to the wellbore. To access the hydrocarbons for production, a perforating gun system may be deployed into the casing string via a tool string. The tool string (e.g., a tubing string, wireline, slick line, coil tubing) lowers the perforating gun system into the casing string to a desired position within the wellbore. Once the perforating gun system is in position such that shaped charges are disposed adjacent to a subterranean formation having hydrocarbons, the shaped charges are detonated. The detonation perforates the casing string, the cementing, and the subterranean formation such that hydrocarbons may flow into the casing string via the perforation.
Traditionally, shaped charges include an explosive material that expels a metal liner outward in a jet to perforate a target material (e.g., casing string, cementing, subterranean formation) upon detonation. Various characteristics of the metal liner (e.g., material, shape, size, density, etc.) may affect velocity, momentum, length, and stability of the jet formation. For example, increasing the density at a tip of a liner and/or decreasing the density at a base of the liner may alter the velocity and momentum gradients of the jet. Having a high velocity jet may be ideal for penetrating relatively hard target materials. However, in some situations, having a higher density at a middle of the liner or at the base of the liner may be ideal for penetrating target materials.
Unfortunately, current manufacturing techniques, which include spinning metal powder in a centrifugal die and pressing the metal powder to form the liner, do not readily allow for intentional density variations in the liner. Indeed, spinning the metal powder tends to drive lower density particles outward such that the metal liners are generally denser proximate the tip of the liner, which may limit their effectiveness on some target materials.
These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the method.
Disclosed herein are systems and methods for segmented shaped charges used in downhole perforating guns systems configured to perforate downhole materials (e.g., casing string, cementing, subterranean formation). In particular, the segmented shaped charges each comprise a plurality of liner segments. As set forth in detail below, the liner segments 312 may each be formed with specific characteristics (e.g., material, shape, size, density, etc.) and oriented within a corresponding shaped charge 120 such that the resulting shaped charge 120 liner may have a particular density gradient, as well as other characteristics, for perforating a target downhole material.
The work string 110 is configured to lower the perforating gun system 112 into a wellbore 114. As illustrated, the wellbore 114 may be lined with casing 116 cemented to a wellbore wall 118. The casing 116 is configured to protect the wellbore 114 from failure (e.g., collapse, erosion) and to provide a fluid path for hydrocarbons during production. To access the hydrocarbons, the work string 110 lowers the perforating gun system 112 to a position such that shaped charges 120 are disposed adjacent to a subterranean formation 122 having the hydrocarbons, and the perforating gun system 112 detonates the shaped charges 120. In some embodiments, the shaped charges 120 may be detonated by the perforating gun system 112. The detonations perforate the casing 116, the cementing, and the subterranean formation 122 in the respective paths of the shaped charge 120 detonations such that hydrocarbons may flow into the casing 116 string via the perforations.
Moreover, the perforating gun system 112 also includes the at least one shaped charge 120 (e.g., a first shaped charge 220, a second shaped charge 222, a third shaped charge 224, and a fourth shaped charge 226). The at least one shaped charge 120 may be mounted within the charge tube 202. At a desired location in the wellbore, the at least one shaped charge 120 is configured to detonate to perforate the casing 116, the cementing, and the subterranean formation 122. A detonating device 228 of the perforating gun system 112 may be configured to initiate detonation of the shaped charges 120. As illustrated, the detonating device 228 may include a detonating cord 230 connected to each shaped charge 120 mounted within the charge tube 202.
As illustrated, the segmented shaped charge liner 302 comprises a plurality of liner segments 312 configured to stack within the shaped charge casing 300. Each liner segment 312 may each be formed with specific characteristics (e.g., material, shape, size, density, density gradient, etc.) and oriented within the shaped charge casing 300 such that the segmented shaped charge liner 302 may have a particular density gradient, as well as other characteristics, for perforating a target downhole material. In the illustrated embodiment, the plurality of liner segments 312 includes a tip liner segment 314, a first intermediate liner segment 316, a second intermediate liner segment 318, and a base liner segment 320 that are stacked to form the segmented shaped charge liner 302 with a hollow conical shape. However, any suitable number of liner segments 312 may be used to form the segmented shaped charge liner 302. For example, the plurality of liner segments 312 may include only the tip liner segment 314 and the base liner segment 320. Alternatively, the plurality of liner segments 312 may include one or more intermediate liner segments stacked between the tip liner segment 314 and the base liner segment 320 to form the segmented shaped charge liner 302.
The tip liner segment 314 is configured to be disposed in the shaped charge casing 300 proximate the initiating end 306 of the shaped charge casing 300. The tip liner segment 314 comprises a first group 322 of compacted metal powder having a hollow cone shape with a tip end 324 and a trailing interface end 326 disposed opposite the tip end 324. The first group 322 of compacted metal powder may comprise a metal, a coated metal, or metal alloy powder selected from the group consisting of iron, steels, copper, brass, bronze, manganese, molybdenum, nickel, tungsten, bismuth, tin, lead, tantalum, aluminum, alloys thereof, and combinations thereof. A small amount of graphite may be included to act as a lubricant. Further, the first group 322 of compacted metal powder may be in a green state. That is, the first group 322 of metal powder is compacted into a desired shape, but not sintered or otherwise fused into a solid liner segment. Fusing the metal powder into a solid liner segment may adversely affect completion operations as the solid liner segment may leave behind a metal slug that blocks the hole formed by other portions of the segmented shaped charge liner 302.
Moreover, as illustrated, the tip liner segment 314 may be formed with a rounded tip end 324 having a radius between 0.03 to 0.5 inches (e.g., between 0.0762 to 1.27 centimeters). However, the tip end 324 may include any suitable shape. Further, the tip end 324 may be disposed more proximate the initiating end 306 of the of the shaped charge casing 300 than the trailing interface end 326 of the tip liner segment 314 such that a diameter (e.g., an inner and/or outer diameter) of the tip liner segment 314 increases in a direction toward a base casing end 328 of the shaped charge casing 300. The diameter of the tip liner segment 314 may increase based at least in part on a slant angle 330 of the tip liner segment 314. In particular, a higher slant angle 330 may result in a larger diameter of the tip liner segment 314 at the trailing interface end 326. The slant angle 330 of the tip liner segment 314 may be between 10.0 to 45.0 degrees. Further, the slant angle 330 of the tip liner segment 314 may be greater than a casing slant angle 332 of the shaped charge casing 300 such that a radial width of the gap between an exterior surface 334 of the tip liner segment 314 and the interior surface 308 of the shaped charge casing 300 decreases in the direction toward the trailing interface end 326 of the tip liner segment 314.
An axial length of the tip liner segment 314, from the tip end 324 to the trailing interface end 326, may be between 12.0 to 50.0 percent of a combined axial length of the plurality of liner segments 312 for a segmented shaped charge liner 302 having two to eight liner segments 312. However, in some embodiments, the axial length of the tip liner segment 314 may be between 15.0 to 35.0 percent of a combined axial length of the plurality of liner segments 312 for a segmented shaped charge liner 302 having two to eight liner segments 312. Moreover, an axial length of each liner segment of the plurality of liner segments 312 may be between 12.0 to 50.0 percent of a combined axial length of the plurality of liner segments 312 for a segmented shaped charge liner 302 having two to eight liner segments 312. However, the axial length of each liner segment may be greater (e.g., between 30.0 to 60.0 percent) for a segmented shaped charge liner 302 having two or three liner segments 312 and less (e.g., between 10.0 to 25.0 percent) for a segmented shaped charge liner 302 having more than four liner segments 312. Further, each of the liner segments 312 may have a distinct axial length based at least in part on a desired density gradient profile for the segmented shaped charge liner 302. For example, in the illustrated embodiment, the axial lengths of the liner segments 312 progressively decrease from the tip liner segment 314 toward the base liner segment 320 such that the density of the segmented shaped charge liner 302 proximate the tip liner segment 314 is greater than the density proximate the base liner segment 320. Alternatively, each of the liner segments 312 may have the same axial length.
An average thickness of the tip liner segment 314 may be between 0.015 to 0.150 inches (e.g., between 0.0381 to 0.381 centimeters). As set forth above, the tip liner segment 314 comprises a hollow cone shape. The thickness of the tip liner segment 314 may be measured between an interior surface 336 of the tip liner segment 314 and the exterior surface 334 of the tip liner segment 314. In some embodiments, the thickness of the tip liner segment 314 may increase in the axial direction from the tip end 324 toward the trailing interface end 326. Alternatively, the tip liner segment 314 may have a uniform thickness. Moreover, an average thickness of each liner segment may be between 0.015 to 0.250 inches (e.g., 0.0381 to 0.635 centimeters). In some embodiments, the average thickness of each liner segment 312 may increase toward a base end 338 of the segmented shaped charge liner 302. For example, as illustrated, the respective average thicknesses may be 0.035 inches (e.g., 0.0889 centimeters) for the tip liner segment 314, 0.036 inches (e.g., 0.09144 centimeters) for the first intermediate liner segment 316, 0.05 inches (e.g., 0.127 centimeters) for the second intermediate liner segment 318, and 0.065 inches (e.g., 0.1651 centimeters) for the base liner segment 320. However, a thickness at each end of the respective liner segments 312 may be the same as a corresponding end of an adjacent liner segment for interfacing purposes.
Each liner segment 312 may have at least one interface end 340 configured to interface with a corresponding interface end of an adjacent liner segment. For example, in the illustrated embodiment, the tip liner segment 314 comprises the trailing interface end 326 mated with a leading first intermediate interface end 342. The trailing interface end 326 and the leading first intermediate interface end 342 may have the same inner and outer diameters such that the respective interface ends 340 may be aligned and form the continuous interior surface 344 and exterior surface 310 for the segmented shaped charge liner 302 between the adjacent liners 312. Further, a trailing first intermediate interface end 346 of the first intermediate liner segment 316 may be mated with a leading second intermediate interface end 348 of the second intermediate liner segment 318, and a trailing second intermediate interface end 350 of the second intermediate liner segment 318 may be mated with a leading base interface end 352 of the base liner segment 320. Alternatively, for an embodiment having only the tip liner segment 314 and the base liner segment 320, the trailing interface end 326 of the tip liner segment 314 may be mated with the leading base interface end 352 of the base liner segment 320.
Moreover, as set forth above, the plurality of liner segments 312 may include at least one intermediate liner segment disposed between the tip liner segment 314 and the base liner segment 320. In the illustrated embodiment, the at least one intermediate liner segment includes the first intermediate liner segment 316, disposed adjacent the tip liner segment 314, and the second intermediate liner segment 318 disposed adjacent the base liner segment 320. The at least one intermediate liner segment comprises a second group 354 of compacted metal powder having a truncated hollow cone shape with a leading intermediate interface end (e.g., the leading first intermediate interface end 342) and a trailing intermediate interface end (e.g., the trailing first intermediate interface end 346). The second group 354 of compacted metal powder may comprise a metal or metal alloy powder selected from the group consisting of iron, steels, copper, brass, bronze, manganese, molybdenum, nickel, tungsten, bismuth, tin, lead, tantalum, aluminum, alloys thereof, and combinations thereof. The second group 354 of compacted metal powder may have the same metal or metal alloy as the first group 322 of compacted metal powder. Alternatively, the second group 354 of compacted metal powder may include a different metal or metal alloy than the first group 322 of compacted metal powder. Further, the second group 354 of compacted metal powder may be in a green state. Additionally, as the at least one intermediate liner segment has a truncated hollow cone shape, the leading intermediate interface end and the trailing intermediate interface end may each have an annular or ring-shaped cross-section. Additionally, the trailing intermediate interface end has a larger diameter than the leading intermediate interface end.
Further, the plurality of liner segments 312 includes the base liner segment 320, which comprises a third group 356 of compacted metal powder having a truncated hollow cone shape. The third group 356 of compacted metal powder may comprise a metal or metal alloy powder selected from the group consisting of iron, steels, copper, brass, bronze, manganese, molybdenum, nickel, tungsten, bismuth, tin, lead, tantalum, aluminum, alloys thereof, and combinations thereof. The third group 356 of compacted metal powder may have the same metal or metal alloy as the first group 322 and/or second group 354 of compacted metal powder. For example, the first group 322, second group 354, and third group 356 of compacted metal powder may each include copper and tungsten materials, perhaps in different proportions. Alternatively, the third group 356 of compacted metal powder may include a different metal or metal alloy than the first group 322 and/or second group 354 of compacted metal powder. For example, the first group 322 of compacted metal powder may include a copper and tungsten material, and the second group 354 and third group 356 of compacted metal powders may each include a steel material. Further, the base liner segment 320 includes the leading base interface end 352 and a trailing base end 358, each having an annular or ring-shaped cross-section. The trailing base end 358 may have a larger diameter than the leading base interface end 352. In some embodiments, an outer diameter at the trailing base end 338 of the base liner segment 320 may be sufficiently large such that an outer surface of the base liner segment 320 contacts the interior surface 308 of the shaped charge casing 300. Such contact may at least partially seal the explosive material 304 from the base casing end 328 of the shaped charge casing 300.
Moreover, as illustrated, each liner segment of the plurality of liner segments 312 comprises at least one interface feature 600 configured to interface with a corresponding interface feature of an adjacent liner segment in the shaped charge casing 300 to restrain at least lateral movement between the liner segment and the adjacent liner segment. The at least one interface feature 600 of each liner segment 312 may include a protrusion, a recess, or some combination thereof. For example, the trailing second intermediate interface end 350 of the second intermediate liner segment 318 may comprise a protrusion 602 (e.g., a ridge) extending out from a surface of the trailing second intermediate interface end 350 and about at least a portion of the circumference of the trailing second intermediate interface end 350. Further, the leading base interface end 352 of the base liner segment 320 may comprise a corresponding recess 604 (e.g., channel) extending into a surface of the leading base interface end 352 and about at least a portion of the circumference of the leading base interface end 352. When stacking the base liner segment 320 on the second intermediate liner segment 318, the protrusion 602 of the second intermediate liner segment 318 may extend into the recess 604 of the base liner segment 320. Such interface features 600 may at least partially restrain lateral movement between the second intermediate liner segment 318 and the base liner segment 320.
Moreover, as set forth above, each liner segment of the plurality of liner segments 312 may comprise a density gradient along an axial length of the liner segment. Each liner segment may have a leading end (e.g., tip end 324, leading first intermediate interface end 342, etc.) and a trailing end (e.g., trailing interface end 326, trailing first intermediate interface end 346, etc.). Generally, the trailing end has a larger diameter than the leading end. The density gradient for each liner segment may include a first mean density between 0.3613 to 0.7948 pounds per cubic inch [e.g., between 10.0 to 22.0 grams/cubic centimeters (g/cm3)] at the leading end of each liner segment and a second mean density at the trailing end of each liner segment. The second mean density may be between 95 to 99 percent of the density of the first mean density. For example, the density gradient for a liner segment may include the first mean density of 10.0 g/cm3 at the leading end and the second mean density of 9.5 g/cm3 at the trailing end. Alternatively, the plurality of liner segments may be inverted such that first mean density is between 95 to 100 percent of the density of the second mean density. The density gradient along the axial length of the liner segments 312 may comprise a gradual transition from the first mean density to the second mean density.
Accordingly, the present disclosure may provide segmented shaped charges and methods for forming segmented shaped charges used in downhole perforating guns systems for perforating downhole materials These systems and methods may include any of the various features disclosed herein, including one or more of the following statements.
Statement 1. A shaped charge liner, comprising: a plurality of liner segments for a shaped charge configured to perforate a sidewall of a wellbore upon detonation, wherein the plurality of liner segments comprises: a tip liner segment comprising a first group of compacted metal powder having a hollow cone shape with a trailing interface end disposed opposite a tip end, wherein the trailing interface end has a larger diameter than the tip end, and wherein the tip liner segment is configured to be disposed in a shaped charge casing of the shaped charge; and a base liner segment comprising a second group of compacted metal powder having a truncated hollow cone shape with a trailing base end disposed opposite a leading base interface end, wherein the trailing base end has a larger diameter than the leading base interface end, and wherein the base liner segment is configured to be disposed at least partially within the shaped charge casing.
Statement 2. The shaped charge liner of statement 1, wherein the plurality of liner segments are configured to stack in the shaped charge casing to form a hollow cone shape.
Statement 3. The shaped charge liner of statement 1 or statement 2, wherein each liner segment of the plurality of liner segments comprises at least one interface feature configured to interface with a corresponding interface feature of an adjacent liner segment in the shaped charge casing to restrain at least lateral movement between the liner segment and the adjacent liner segment.
Statement 4. The shaped charge liner of any preceding statement, wherein the at least one interface feature of each liner segment comprises a protrusion, a recess, or some combination thereof.
Statement 5. The shaped charge liner of any preceding statement, wherein each liner segment of the plurality of liner segments comprises a density gradient along an axial length of the liner segment.
Statement 6. The shaped charge liner of any preceding statement, wherein the density gradient comprises a first mean density between about 10 g/cm3 to about 22 g/cm3 at a leading end of each liner segment of the plurality of liner segments and a second mean density at a trailing end of each liner segment of the plurality of liner segments, wherein the second mean density is between about 95 percent to about 99 percent of the first mean density, and wherein the trailing end has a greater diameter than the leading end.
Statement 7. The shaped charge liner of any preceding statement, wherein an axial length of each liner segment is between about 12 percent to about 50 percent of a combined axial length of the plurality of liner segments.
Statement 8. The shaped charge liner of any preceding statement, wherein a thickness of each liner segment is between about 0.035 inches to about 0.11 inches.
Statement 9. The shaped charge liner of any preceding statement, wherein the first group of compacted metal powder and the second group of compacted metal powder each comprise at least one metal or at least one metal alloy powder selected from the group consisting of iron, steel, copper, brass, bronze, manganese, molybdenum, nickel, tungsten, bismuth, tin, lead, tantalum, aluminum, an alloy thereof, and combinations thereof.
Statement 10. The shaped charge liner of any preceding statement, where the plurality of liner segments further comprises at least one intermediate liner segment configured to be disposed between the tip liner segment and the base liner segment in the shaped charge casing, and wherein the tip liner segment, the intermediate liner segment, and the base liner segment are configured to stack in the shaped charge casing to form a hollow cone shape.
Statement 11. The shaped charge liner of any preceding statement, wherein the at least one intermediate liner segment comprises a first intermediate liner segment and a second intermediate liner segment, wherein the first intermediate liner segment is disposed adjacent the tip liner segment, and wherein the second intermediate liner segment is disposed adjacent the base liner segment.
Statement 12. A method of making a segmented shaped charge liner, comprising: placing a respective group of metal powder into each die of a plurality of dies; rotating each die of a plurality of dies to drive the respective groups of metal powder out and up corresponding inner walls of the plurality of dies via centrifugal force; and pressing a respective punch into each die of a plurality of dies to compact the respective groups of metal powder and form corresponding liner segments, wherein the liner segments are configured to stack in a shaped charge casing of a shaped charge that is configured to perforate a sidewall of a wellbore upon detonation.
Statement 13. The method of statement 12, wherein the plurality of dies comprise a cone shaped die configured to receive a corresponding cone shaped punch for forming a tip liner segment having a hollow cone shape, and wherein the plurality of dies further comprise at least one truncated cone shaped die configured to receive a corresponding truncated cone shaped punch for forming at least one liner segment having a hollow truncated cone shape.
Statement 14. The method of statement 12 or statement 13, wherein the plurality of dies comprise: a cone shaped die configured to receive a corresponding cone shaped punch for forming a tip liner segment having a hollow cone shape; a first truncated cone shaped die configured to receive a first truncated cone shaped punch for forming a first intermediate liner segment having a truncated hollow cone shape, wherein the first intermediate liner segment has a larger mean diameter than the tip liner segment; a second truncated cone shaped die configured to receive a second truncated cone shaped punch for forming a second intermediate liner segment having a truncated hollow cone shape, wherein the second intermediate liner segment has a larger mean diameter than the first intermediate liner segment; and a third truncated cone shaped die configured to receive a third truncated cone shaped punch for forming a base liner segment having a truncated hollow cone shape, wherein the base liner segment has a larger mean diameter than the second intermediate liner segment.
Statement 15. The method of any one of statements 12-14, further comprising the step of stacking the liner segments in the shaped charge casing to form a hollow cone shape liner disposed at least partially in the shaped charge casing.
Statement 16. The method of any one of statements 12-14, further comprising the steps of: stacking the liner segments within a secondary cone shaped die such that the stacked liner segments form a hollow cone shape; and pressing a secondary cone shaped punch into the secondary cone shaped die to merge the liner segments into a continuous liner configured to be disposed in a shaped charge casing.
Statement 17. The method of any one of statements 12-16, wherein rotating each die of a plurality of dies to drive the respective groups of metal powder radially outward and vertically up the corresponding inner walls of the plurality of dies via centrifugal force segregates metal particles of the respective groups of metal powder by density such that the liner segments comprise a density gradient along an axial length of each respective liner segment.
Statement 18. The method of any one of statements 12-18, wherein each die of the plurality of dies is oriented such that respective diameters of the corresponding inner walls of the plurality of dies increase in the upward direction.
Statement 19. A system for making a segmented shaped charge liner, comprising: a first press assembly comprising a cone shaped punch and a cone shaped die, wherein the cone shaped die is configured to receive a first group of metal powder, and wherein the cone shaped punch is configured to press the first group of metal powder against a first inner wall of the cone shaped die to compact the first group of metal powder and form a tip liner segment having a hollow cone shape; and a second press assembly comprising a truncated cone shaped punch and a truncated cone shaped die, wherein the truncated cone shaped die is configured to receive a second group of metal powder, and wherein the truncated cone shaped punch is configured to press the second group of metal powder against a second inner wall of the truncated cone shaped die to compact the second group of metal powder and form a base liner segment having a truncated hollow cone shape, wherein the tip liner segment and the base liner segment are configured to be disposed in a shaped charge casing of a shaped charge that is configured to perforate a sidewall of a wellbore upon detonation.
Statement 20. The system of statement 19, further comprising a secondary press assembly comprising a secondary cone shaped punch and a secondary cone shaped die, wherein the secondary cone shaped die is configured to receive the tip liner segment and the base liner segment, and wherein the secondary cone shaped punch is configured to press the tip liner segment and the base liner segment against a third inner wall of the secondary cone shaped die and against each other to form a continuous liner having a hollow cone shape configured to be disposed in a shaped charge casing of a shaped charge that is configured to perforate a sidewall of a wellbore upon detonation.
Therefore, the present embodiments are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.
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| Number | Date | Country |
|---|---|---|
| 110145972 | Jun 2021 | CN |
| 110145972 | Jun 2021 | CN |
| Entry |
|---|
| Machine translation of CN-110145972-B (Year: 2021). |
| International Search Report and Written Opinion for International Patent Application No. PCT/US2022/030194 dated Feb. 8, 2023. |
| Number | Date | Country | |
|---|---|---|---|
| 20230364673 A1 | Nov 2023 | US |
