Certain downhole operations involve placement of elements in a downhole environment, where the element performs its function, and is then removed. For example, elements such as ball/ball seat assemblies and fracture (frac) plugs are downhole elements used to seal off lower zones in a borehole in order to carry out a hydraulic fracturing process (also referred to in the art as “fracking”) to break up different zones of reservoir rock. After the fracking operation, the ball/ball seat or plugs are then removed to allow, inter alia, fluid flow to or from the fractured rock.
Balls and/or ball seats, and frac plugs, can be formed of a corrodible material so that they need not be physically removed intact from the downhole environment. In this way, when the operation involving the ball/ball seat or frac plug is completed, the ball, ball seat, and/or frac plug is dissolved away. Otherwise, the downhole article may have to remain in the hole for a longer period than is necessary for the operation.
To facilitate removal, such elements can be formed of a material that reacts with the ambient downhole environment so that they need not be physically removed by, for example, a mechanical operation, but instead corrode or dissolve in the downhole environment. In order to employ dissolution or corrosion to remove downhole elements, it is very desirable to develop downhole articles and methods of their use whereby the dissolution or corrosion and removal of these elements may be selectively controlled.
In an exemplary embodiment, a selectively corrodible downhole article is disclosed. The article includes a movable cylindrical member comprising a first section and an axially separated second section, the first section comprising a first material having a first galvanic activity, the second section comprising a second material having a second galvanic activity, the first galvanic activity being greater than the second galvanic activity, the first section being electrically isolated from the second section. The article also includes a fixed member disposed on the cylindrical member and configured for electrical contact with the first section or the second section, the fixed member comprising an intermediate material having an intermediate galvanic activity, the intermediate galvanic activity being intermediate the first galvanic activity and the second galvanic activity, the movable cylindrical member configured for movement from a first position where the first section is disposed on and in electrical contact with the fixed member and a second position where the second section is disposed on and in electrical contact with the fixed member, wherein in the first position, the first section is configured for selective dissolution, and wherein in the second position, the fixed member is configured for selective dissolution.
In another exemplary embodiment, a method of removing a selectively corrodible downhole article is disclosed. The method includes disposing downhole a selectively corrodible downhole article, comprising: a movable cylindrical member comprising a first section and an axially separated second section, the first section comprising a first material having a first galvanic activity, the second section comprising a second material having a second galvanic activity, the first galvanic activity being greater than the second galvanic activity, the first section being electrically isolated from the second section; and a fixed member disposed on the cylindrical member and configured for electrical contact with the first section or the second section, the fixed member comprising an intermediate material having an intermediate galvanic activity, the intermediate galvanic activity being intermediate the first galvanic activity and the second galvanic activity, the movable cylindrical member configured for movement from a first position where the first section is disposed on and in electrical contact with the fixed member and a second position where the second section is disposed on and in electrical contact with the fixed member, wherein in the first position, the first section is configured for selective dissolution, and wherein in the second position, the fixed member is configured for selective dissolution. The method also includes exposing the selectively corrodible downhole article to a first wellbore fluid while the movable cylindrical member is in the first position, wherein the first section is selectively dissolved. The method further includes moving the movable cylindrical member to the second position and exposing the selectively corrodible metallic downhole article to a second wellbore fluid, wherein the fixed member is selectively dissolved.
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
Referring to the figures, and particularly
The article 10 includes a movable member, such as a movable cylindrical member 12, comprising a first section 14 and an axially separated second section 16. The first section 14 comprising a first material 18 having a first galvanic activity. The second section 16 includes a second material 20 having a second galvanic activity. The first galvanic activity is greater than the second galvanic activity, such that it has a greater tendency to corrode in a given wellbore fluid as an electrolyte. The first section 14 is electrically isolated from the second section 16. Electrical isolation may be accomplished by any suitable electrical isolator 22. A suitable electrical isolator may include any suitable electrically insulating material, particularly an electrically insulating polymer or ceramic, or a combination thereof.
The article 10 also includes a fixed member 24 disposed on the movable cylindrical member 12 or movable cylindrical member 12 may be disposed within fixed member 24. The movable cylindrical member 12 and fixed member 24 are both electrically conductive. The fixed member 24 is configured for electrical contact with the first section 14 or the second section 16, the fixed member 24 comprising an intermediate material 26 having an intermediate galvanic activity, the intermediate galvanic activity being intermediate the first galvanic activity and the second galvanic activity. The movable cylindrical member 12 is configured for movement from a first position 28 where the first section 14 is disposed on and in electrical contact with the fixed member 24 and a second position 30 where the second section 16 is disposed on and in electrical contact with the fixed member 24. In the first position 28, the first section 14 is configured for selective dissolution because the first material 18 is more galvanically active (i.e., is more reactive) than the intermediate material 26. In the second position, the fixed member 24 is configured for selective dissolution because the intermediate material 26 is more galvanically active than the second material 20. The first material 18, intermediate material 26 and second material 20 may each be, for example, a different metal from the galvanic series having the relative activities described herein. The first material 18, intermediate material 26 and second material 20 contact each other as described herein in the presence of a wellbore fluid that comprises an electrolyte, such as for example a brine, acidizing fluid, drilling mud or the like.
Referring to
Referring to
Referring to
Referring to
The first material 18 may, for example, comprise any suitable corrodible, high reactivity metal. In one embodiment, the first material is magnesium, which is anodic with respect to the intermediate material 26 and second material 20. The first material 18 may includes any material suitable for use in a downhole environment, provided the first material 18 is more galvanically active in the downhole environment relative to the intermediate material 26 and second material 20. In particular, first material 18 may be selected from the materials described herein for use as intermediate material 26, so long as the first material 18 is selected to be more galvanically active than the intermediate material 26.
The intermediate material 26 may, for example, comprise a corrodible, intermediate reactivity metal. In one embodiment, the intermediate material 26 comprises magnesium, aluminum, manganese or zinc, or an alloy thereof, or a combination comprising at least one of the foregoing. Magnesium alloys include any such alloy which is corrodible in a corrosive environment including those typically encountered downhole, such as an aqueous environment which includes salt (i.e., brine), or an acidic or corrosive agent such as hydrogen sulfide, hydrochloric acid, or other such corrosive agents. Magnesium alloys suitable for use include alloys of magnesium with aluminum (Al), cadmium (Cd), calcium (Ca), cobalt (Co), copper (Cu), iron (Fe), manganese (Mn), nickel (Ni), silicon (Si), silver (Ag), strontium (Sr), thorium (Th), zinc (Zn), or zirconium (Zr), or a combination comprising at least one of these elements. Particularly useful alloys can be prepared from magnesium alloy particles including those prepared from magnesium alloyed with Al, Ni, W, Co, Cu, Fe, or other metals. Alloying or trace elements can be included in varying amounts to adjust the corrosion rate of the magnesium. For example, four of these elements (cadmium, calcium, silver, and zinc) have to mild-to-moderate accelerating effects on corrosion rates, whereas four others (copper, cobalt, iron, and nickel) have a still greater accelerating effect on corrosion. Exemplary commercially available magnesium alloys which include different combinations of the above alloying elements to achieve different degrees of corrosion resistance include, but are not limited to, for example, those alloyed with aluminum, strontium, and manganese such as AJ62, AJ50x, AJ51x, and AJ52x alloys, and those alloyed with aluminum, zinc, and manganese which include AZ91A-E alloys.
It will be appreciated that alloys having corrosion rates greater than those of the above exemplary alloys are contemplated as being useful herein. For example, nickel has been found to be useful in decreasing the corrosion resistance (i.e., increasing the corrosion rate) of magnesium alloys when included in amounts less than or equal to about 0.5 wt %, specifically less than or equal to about 0.4 wt %, and more specifically less than or equal to about 0.3 wt %, to provide a useful corrosion rate for the corrodible downhole article. The above magnesium alloys are useful for forming the intermediate material 26, and may be formed into the desired shape and size by casting, forging and machining.
In one embodiment, powders of magnesium or the magnesium alloys described are useful for forming the fixed member 24 as a powder compact. The magnesium alloy powder generally has a particle size of from about 50 to about 250 micrometers (μm), and more specifically about 60 to about 140 μm. The powder may be further coated using a method such as chemical vapor deposition, anodization or the like, or admixed by physical method such as cryo-milling, ball milling, or the like, with a metal or metal oxide, nitride or carbide, such as Al, Ni, W, Co, Cu or Fe, or oxides, nitrides or carbides thereof, or an alloy thereof, or a combination thereof. The coatings may have any suitable thickness, including nanoscale coatings having an average thickness of about 5 nm to about 2500 nm. Such coated powders are referred to herein as controlled electrolytic materials (CEM). The CEM is then molded or compressed into the desired shape by, for example, cold compression or pressing using an isostatic press at about 40 to about 80 ksi (about 275 to about 550 MPa), followed by extrusion, forging, or sintering, or machining, to provide a core having the desired shape and dimensions. The CEM materials may include the cellular nanomatrix materials formed from the powder materials described, for example, in commonly assigned, co-pending U.S. application Ser. No. 12/633,682 filed on Dec. 8, 2009; U.S. application Ser. No. 13/220,824 filed on Aug. 30, 2011; U.S. application Ser. No. 13/220,832 filed on Aug. 30, 2011; and U.S. application Ser. No. 13/220,822 filed on Aug. 30, 2011, which are incorporated herein by reference in their entirety.
It will be understood that the magnesium alloy or CEM, may thus have any corrosion rate necessary to achieve the desired performance of the article. In a specific embodiment, the magnesium alloy or CEM used to form the fixed member 24 has a corrosion rate of about 0.1 to about 150 mg/cm2/hour, specifically about 1 to about 15 mg/cm2/hour using aqueous 3 wt % KCl at 200° F. (93° C.).
The second material 20 is, in an embodiment, any material that is galvanically less active (having a lower reactivity than the first material 18 and intermediate material 26), based on, for example, the saltwater galvanic series. The second material 20 may include a lower reactivity metal such as various grades of steels, tungsten, chromium, nickel, copper, cobalt, iron, or an alloy thereof, or a combination comprising at least one of the foregoing. In one embodiment, the second material 20 may be substantially non-corrodible or inert in the downhole environment. In another embodiment, the second material 20 may be resistant to corrosion by a corrosive material. As used herein, “resistant” means the second material is not etched or corroded by any corrosive downhole conditions encountered (i.e., brine, hydrogen sulfide, etc., at pressures greater than atmospheric pressure, and at temperatures in excess of 50° C.), or any wellbore 70 fluid used in conjunction with the articles or methods described herein.
By selecting the reactivity of the first and second materials to have a greater or lesser difference in their corrosion potentials, the higher reactivity material (e.g., high reactivity metal) corrodes at a faster or slower rate, respectively. Generally, for metals in the galvanic series, the order of metals, from more noble (i.e., less active and more cathodic) to less noble (i.e., more active and more anodic) includes for example steel, tungsten, chromium, nickel, cobalt, copper, iron, aluminum, zinc, and magnesium.
When the dissimilar metal combinations described herein are brought into electrical contact in the presence of an electrolyte, an electrochemical potential is generated between the anodic, more galvanically active material and the cathodic, less galvanically active material. The greater the difference in corrosion potential between the dissimilar metals, the greater the electrical potential generated. In such an arrangement, the cathodic material is protected from corrosion by the anodic material, where the anodic material corrodes as a sacrificial anode. Corrosion of the fixed member 24, for example, in brines and other electrolytes can be controlled (eliminated or substantially reduced) when it is in the first position where it is in electrical contact with the more active first section 14. Electrically coupling the anodic material and the cathodic material with an electrolyte also produces an electrical potential that may also be used to power a downhole device, such as, for example, a device for downhole signaling or sensing.
Referring to
Disposing 110 the selectively corrodible downhole article 10 downhole may be accomplished in any suitable manner, including delivery downhole by use of a wireline, slickline, tubular string or the like. The movable cylindrical member 12 and fixed member 24 may be disposed downhole as individual components, or together as part of an assembly. Whether as part of the installation or afterwards, the movable cylindrical member 12 is placed in the first position 28 where the first section 14 is disposed on and in electrical contact with the fixed member 24.
Once the first section 14 is disposed on and in electrical contact with the fixed member 24, the method 100 also includes exposing 120 the selectively corrodible downhole article to a first wellbore fluid 72 while the movable cylindrical member is in the first position, wherein the first section is selectively dissolved. The first wellbore fluid 72 may include an aqueous or non-aqueous electrolyte, depending on the application and controllability of ambient conditions. In the downhole environment, controlling the ambient conditions to exclude moisture is not practical, and hence, under such conditions, the electrolyte is generally an aqueous electrolyte. Aqueous electrolytes may include water or a salt dissolved in water, such as a brine, or an acid, or a combination comprising at least one of the foregoing. Exposing 120 the selectively corrodible downhole article 10 to a first wellbore fluid 72 may include performing a downhole operation, such as a fracking, for example. During exposing 120, the movable cylindrical member 12 is in the first position 28 where the first section 14 is disposed on and in electrical contact with the fixed member 24. In the first position 28, the more galvanically active first material 18 of the first section 14 acts as an anode and is selectively dissolved or corroded while the less galvanically active intermediate material 26 of the fixed member 24 acts as a cathode and is selectively protected from dissolution or corrosion. The movable cylindrical member 12, particularly the first section 14, and the fixed member 24 may be designed for the wellbore operation for which they are to be used to provide sufficient material for the dissolution or corrosion that occurs during the downhole operation that is to be performed.
The method 100 further includes moving 130 the movable cylindrical member 12 to the second position 30. In the second position 30, the second section 16 is disposed on and in electrical contact with the fixed member 24. In the second position 30, the fixed member 24 is configured for selective dissolution because the intermediate material 26 is more galvanically active than the second material 20. In the second position 30, the more galvanically active intermediate material 26 of the fixed member 24 acts as an anode and is selectively dissolved or corroded while the less galvanically active second material 20 of the second section 16 acts as a cathode and is selectively protected from dissolution or corrosion. The fixed member 24 and intermediate material 26 may also be selected and designed for the wellbore operation for which they are to be used, such as to provide rapid dissolution or corrosion and removal from the wellbore 70. Removing the fixed member 24 may, for example, be used to open the wellbore for a subsequent wellbore operation, such as a completion or production operation.
The method 100 then includes exposing 140 the selectively corrodible metallic downhole article 10 to a second wellbore 74 fluid, wherein the fixed member 24 is selectively dissolved. This may also include the selective dissolution of other members, such as the ball 50 or plug 60, as described herein. The second wellbore fluid may be the same wellbore fluid as the first wellbore fluid 72. Alternately, the second wellbore fluid 74 and first wellbore fluid 72 may be different wellbore fluids.
All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including at least one of that term (e.g., the colorant(s) includes at least one colorants). “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. As used herein, “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. All references are incorporated herein by reference.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).
While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
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