Patent Application
20240401443
One embodiment of the invention is generally directed to downhole systems and equipment such as may be employed in oil and gas exploration, and production. One particular example embodiment comprises a semi-automatic perforation system configured for single-fire, or multi-fire, operations in a downhole environment.
Perforation guns are used in downhole environments to fracture a formation so as to enable the injection of pressurized fluid into the formation which will then force gas, oil, and other materials out of the formation. These materials may then be collected. A perforation, or ‘perf,’ gun may fracture the formation using shape charges. Once the perf gun has fired all its shape charges, the perf gun is then completely retracted out of the wellbore. At this stage, the perf gun is no longer useable and may be recycled or otherwise disposed of.
Once the perf gun starts to fire the shape charges, the perf gun may lose electrical and/or command access through the section of the tool, that is, the perf gun, that fired the charges. Any tools below, or downhole of, the fired shape charge may likewise lose power and communication with the surface.
Many wells for which hydraulic fracturing will be performed will require more than one perf gun per frac. The number of perf guns needed may vary, but a typical oil and gas well may require anywhere from about 30 to 100 fracturing stages, each of which requires a respective perf gun. Thus, conventional approaches to hydraulic fracturing are time consuming at least insofar as perf guns have to be sent downhole, and then retrieved, for each stage of the well. Moreover, because the perf guns are a consumable item and must be replaced after a fracturing operation has been performed for a stage, the use of conventional perf guns is expensive.
One embodiment of the invention is concerned with a downhole system that includes a housing configured to be releasably connected to a tether, projectile fire control circuitry disposed within the housing, a block chamber connected to the housing, and the block chamber includes one or more reloadable chambers each configured to be loaded with a respective projectile, and a firing system operable to directly, or indirectly, control the firing of a projectile, in response to a command issued by the projectile fire control circuitry.
As will be apparent from this disclosure, example embodiments of the invention may be advantageous in various respects. For example, an embodiment may avoid the need to send and retrieve multiple frac guns in order to perform all the stages of a frac. An embodiment may operate to frac a well more quickly than an approach that requires multiple frac guns. An embodiment may enable a frac to be performed less expensively as compared with conventional approaches. Various other advantages of some embodiments of the invention will be apparent from this disclosure.
It should be noted that nothing herein should be construed as constituting an essential or indispensable element of any invention or embodiment. Rather, and as the person of ordinary skill in the art will readily appreciate, various aspects of the disclosed embodiments may be combined in a variety of ways so as to define yet further embodiments. Such further embodiments are considered as being within the scope of this disclosure. As well, none of the embodiments embraced within the scope of this disclosure should be construed as resolving, or being limited to the resolution of, any particular problem(s). Nor should such embodiments be construed to implement, or be limited to implementation of, any particular effect(s).
The appended drawings contain figures of various example embodiments to further illustrate and clarify the above and other aspects of example embodiments of the invention. It will be appreciated that these drawings depict only example embodiments of the invention and are not intended to limit its scope. Example embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.
Details are now provided concerning aspects of example embodiments of the invention, and associated operating environments. Such embodiments may be employed in connection with downhole exploration and mining processes including, but not limited to, gas and oil exploration and mining. The scope of the invention is not limited to any particular application or use case however.
In an oil/gas exploration/production context, various processes and operations may need to be performed before the actual production of oil, gas, and/or other materials, can take place. Many of such processes and operations may be implemented upstream, that is, upstream of a well head, or other delivery point, of a fossil fuel production system. Some of these processes and operations are discussed in more detail below.
The first process that may take place is the drilling of a well. The drilling operation may comprise a rig drilling a vertical and or horizontal wellbore that may be deep below the surface of the earth. Once the wellbore is drilled, the rig may run multiple sections of casing, or pipe, that may protect the wellbore from collapsing, protect other formations from contaminant, allow for completions, and/or remedial work to take place inside the well later. Once the rig has run casing to the bottom of the wellbore, cement is pumped and fills the void between the casing and the borehole, that is, the wellbore, from the bottom of the well to the surface. Once the wellbore is cased and cemented in place, the well is ready for a frac'ing process.
After the wellbore is cased and cemented, the next process to take place is frac'ing the well. Frac'ing is a process that may comprise pumping large amounts of water and sand down the well, thereby pressurizing the formation and creating a fracture by way of which oil and gas in the formation can enter the wellbore. This frac'ing process may involve a variety of operations, which are denoted as ‘steps’ in the following discussion, as well as support equipment and materials at the surface.
An apparatus operable to perform a plug and perf process may comprise a perf gun, a setting tool, and a plug, all of which may be configured and assembled in a single assembly. The perf gun may comprise a metal tubular tool that includes a number of shape charges that may be rigidly positioned, within the perf gun, to fire in more than one direction. In the case of conventional processes and conventional equipment, the perf gun may not be used more than one time and, as such, may be a consumable item, that is, a single use tool. The plug may be a dissolvable composite, metal, or non-dissolvable composite that serves to create a seal, or barrier, in the wellbore, so that material in the wellbore cannot flow past the plug. The setting tool may comprise an explosive device that is positioned between the perf gun and the plug. The setting tool is used to set the plug and allow the perf gun and setting tool to come off the plug once the plug is set in the wellbore.
This apparatus, that is, the apparatus that includes the perf gun, setting tool, and plug, is then connected to wireline. Once connected to wireline, the apparatus may be staged inside the wellhead and then pumped down the wellbore to a predetermined location. Once the apparatus reaches the predetermined location in the wellbore, the setting tool is activated by a command from the surface sent down the wireline. Once activated, the setting tool sets the plug in the wellbore. Wireline then may start firing the shape charges in the perf gun while the remainder of the apparatus, that is, the perf gun and setting tool, is being retracted back up the wellbore, or ‘uphole.’ This new section of perforated casing may be called a stage.
Once the perf gun starts to fire the shape charges, the perf gun may lose electrical and/or command access through that section of tool or any tool below the fired shape charge. Once the perf gun has fired all its shape charges, the perf gun is then completely retracted out of the wellbore. At this stage, the perf gun is no longer useable and may be recycled or otherwise disposed of. As noted herein, many wells that require hydraulic fracturing will require more than one perf gun per frac. After the plug and perf operations are completed, the next step of the frac and completion process may be implemented.
After the wellbore is perforated at step 1, the well may then be frac'd. To frac a well, a variety of equipment and material is required to operate at the surface. The equipment may comprise, but is not limited to, high-pressure pumps, a blender to mix sand, chemicals, and water, sand trucks, water tanks, a data/command vehicle, a crane, a wireline vehicle, and a large manifold to connect piping and equipment to the wellhead. The material required to fracture the well may comprise, but is not limited to, a combination of water, sand, and chemicals. A number of individuals are also required to operate all the equipment at the surface.
To frac the well now that it is perforated, water, sand, and chemicals are pumped down the wellbore at high rates until those materials reach the plug that has created a barrier in the wellbore. The water, sand, and chemical, with nowhere to go, is forced into the perforations created by the perf gun/shape charges. As the pressure builds up inside the wellbore and perforations, the formation then fractures, and sand and water now enter the fractures. The sand is used to hold the fractures open so that gas, oil, and other materials can be forced out of the formation and into the well. Note that not all perforations created during the perforation process may fracture. In some cases, it may be typical that only 75% or fewer of the perforations created in a given stage may fracture.
After the first stage, that is, stage 1, of the wellbore has been frac'd (see Step 2 above), the next step, that is, Step 3, may be to pump a new perf gun assembly with a new plug, and possibly a new setting tool, down the wellbore. The assembly may be pumped down the wellbore until it reaches the first set of perforations and cannot go any further. The assembly may then be pulled up to a predetermined location in the well and then set its plug and begin firing the shape charges until all shape charges are fired, after which the assembly may then be pulled out of the hole by wireline. This second stage of the well may then be frac'd. These operations may continue until the wellbore is completely perforated and frac'd.
An embodiment of the invention may include, but is not limited to, a reusable perforating system that may be configured and operable for multiple uses, and which is not destroyed after firing its bullets, or projectiles. Because the perf system may be reusable, an embodiment may avoid the accumulation, in the wellbore, of debris that is typically associated with single use perf guns that have been destroyed.
That is, and in contrast with conventional equipment and methods, the perf system and one or more of its individual components, according to one or more embodiments, may be used for multiple perf operations rather than for only a single operation as in the case of conventional equipment and processes. In an embodiment then, such a perf system, and its components, are thus not consumable items.
Some further example embodiments are directed to, among other things, the systems and equipment listed hereafter.
A perforation system that may use caseless projectiles or bullets that do not require a cartridge or housing.
A perforation system which, when a perf gun is fired, may be reloaded and may not lose power or commands to other parts of the perforation system or additional tools or assemblies that may be assembled with the perforation system.
A perforation system that may be pumped downhole and allow the operator to choose the order in which bullets, or other projectiles, are fired, such as choosing which projectile to fire first, and/or how many perforations to fire per stage, without losing command power/command to the system after firing.
A perforation system that may remain in the wellbore including before, during, and after the frac and maintain a tether to the surface and/or other downhole equipment, or may operate autonomously without losing power or command/electrical signal capabilities throughout the tool or other tools and assemblies attached to the perforation system.
A perforation system which, when employed in some methods, may enable an operator to reduce the amount of water, proppant, and power consumption, needed to perform an otherwise conventional frac and, in turn, may reduce the carbon footprint created during the frac. Note that as used herein, ‘proppant’ includes, but is not limited to, solid materials, such as sand or man-made ceramic materials which, when pumped into a fracture created by a frac'ing process, server to keep the hydraulic fracture open, during and/or following a frac'ing process.
A perforation system which when employed in some methods, may enable the operator and service companies to eliminate, or significantly reduce, fuel consumption, and provide grid power to, but not limited to, the frac equipment at the surface, wireline, trucks, and other equipment used to frac a well.
A perforation system that may create perforations that significantly reduce the amount of friction needed to be overcome while pumping frac fluid, and in turn thereby reducing the treating pressure requirements at the surface and frac pressure created downhole.
A perforation system which, when assembled with other tools or devices, may eliminate the need for plugs or sleeves and, in turn, may eliminate the need to reenter the wellbore with drilling equipment to mill up, that is, destroy, the plugs, or actuate the sleeves.
Following is a description of one example embodiment of the invention. This description is provided by way of illustration, and is not intended to limit the scope of the invention in any way.
A single or multi-fire semi-automatic perforation system, or simply ‘perf system,’ may comprise, in an embodiment, a block chamber that may comprise one or more bullets or projectiles and, but not limited to, propellant or increments for propelling the projectiles. Example bullets, or more generally, ‘projectiles,’ may be caseless, that is, not housed within, nor includes, a casing. This configuration of projectiles may eliminate the need to eject or discharge a used cartridge or case during operation once the perf system has fired.
The perf system may comprise a block chamber that may house multiple bullets, or other projectiles. In an embodiment, a mix of different projectiles may be contained in the block chamber. The projectiles may be hermetically sealed into the block chamber and be exposed to the wellbore environment. An ignitable material such as a propellant or increment, may be positioned below or behind each of the projectiles. A hermetically sealed electrical, mechanical, or electro-mechanical primer may be positioned so as to ignite the propellant and may be exposed to the wellbore environment after a projectile is fired. The primers may be wired to a perforation detonation controller that may be housed within a board enclosed within the perf system. The board may send signals or commands to a primer to fire a projectile. The perf system comprise a blank to ensure safety. That is, a perf system may be configured such that the blank is fired first, before the rest of the system can be activated, or goes live. The projectiles may be fired in any sequence, with respect to each other, and in an embodiment, two or more projectiles may be fired simultaneously.
An embodiment of the perf system may also comprise a magazine that houses one or more bullets or projectiles. The bullets or projectiles may be automatically loaded into a barrel, or chamber by, for example, a spring or actuation device that pushes the bullets, or projectiles down or up the magazine and into the barrel or chamber. Once the bullet, or projectile, which may comprise a primer, is chambered in the barrel, the projectile may be fired. In an embodiment, firing of the projectile may be initiated by an electrical mechanism, mechanical mechanism, or electro-mechanical system or firing pin, or any other system or mechanism operable to selectively impact the primer so as to cause the primer to ignite the propellant, causing the projectile to be fired. The bullets or projectiles that may be used with the magazine system may also be caseless, that is, not housed within a cartridge that must be ejected or discharged. The caseless configuration may reduce or eliminate any debris or waste that may otherwise be generated during operation of the perf system.
In an embodiment, the caseless bullets, or projectiles, may be incorporated with devices inside of the jacket that enable the projectile to fragment, or explode, sometime during or after impact with the formation. The bullets, or projectiles, may also comprise other devices such as tracers, or smart technology such as nano technology, that may be released from the bullet sometime during impact or after. The bullets, or projectiles, may also be made of a dissolvable material that may dissolve over time after the bullet, or projectile, is fired.
In an embodiment, nano technology may include, but is not limited to, nanobots, nano-technology that may comprise nano tubes configured and operable to deliver high or low frequency precision signals. In an embodiment, the signals may be encoded within the nanotubes, which in turn may enable the nanobots to communicate with other nanobots and/or to transmit any type of information to components such as, but not limited to, a receiver that may be part of the downhole tool assembly.
In an embodiment, a projectile, such as a bullet for example, may house smart nanobots that are released from the bullet once the bullet fragments. The nanobots may comprise polymers, ceramics, and exotic alloys for armor. The nanobots may be lodged in the perforation that has been made when the bullet penetrates the well casing and cement and lodges itself into the formation. After the nanobots have been released, when the formation fractures during the frac, the nanobots may travel throughout the fractures and collectively form a mesh network that may be used to map a formation and communicate information back to the perf gun and/or to an uphole or surface location.
In an embodiment, the perf system may be used downhole in oil and gas operations. When thus employed, the perf system may operate to create perforations in structures including, but not limited to, casing or tubular member inside the wellbore, and geological formations. These perforations may be created, for example, during remedial operations, during a frac, and/or at any other appropriate times.
In an embodiment, a perf system may be housed inside of structures including, but not limited to, a tubular or cylindrical tool, which may be made of metal for example. The tool may comprise a portable control board, or CPU (central processing unit), to command or electrically control the perf system. The CPU may be controlled, such as by a user at the surface, by a master control unit that delivers commands through, for example, an i2c or CAN bus system. Electrical switches or connectors may be used on either end of the perf system to pass controls throughout the system and/or to other tools or devices that may be assembled together with the perf system.
In an embodiment, a perf system may be run in the wellbore with multiple tools assembled to it such as, but not limited to, optical systems, sealing systems, tractors or other propulsion devices, logging systems or devices, or any tool or device chosen by an operator to run in conjunction with the perf system. The perf system may be powered by various power sources including, but not limited to, batteries for autonomous operations in the wellbore when the perf system is not tethered to power at the surface. The perf system may also be tethered to a power source located at the surface, which in turn, may continue to supply power to the perf system or other tools that may be connected or assembled with the perf system. The perf system may also be run with, but not limited to, coiled tubing or stick pipe run by a rig at the surface. In an embodiment, a perf system may also remain in the wellbore before, during, and after the frac, and the perf system may remain mechanically and electrically operable before, during, and after the frac.
Turning now to
A connection device 104 may comprise a cable head connection which may be coupled to the perf system 100.
A controls housing 106 may house one or more PCBs (printed circuit boards), master control units, CPUs, and/or modems. A controller stored in the controls housing 106 may receive and send data, or signals, to the perf system or back to the surface during operation. The controls housing 106 may also include, for example, a pressure sensor, temperature, sensors, accelerometers, or an optical device or sensor that may record internal and or external data.
The materials used for manufacturing the controls housing 106 may include, but are not limited to, aluminum, manganese, zinc, or other bronze alloys. Nickel alloys or combinations of, but not limited to nickel with materials such as iron, chromium, copper, or molybdenum. Stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese. Aluminum alloys or combinations of, but not limited to, zinc, copper, or iron. Other materials may also include, but not limited to, iron, titanium, polymers or plastics, carbon fiber, or tin. The controls housing 3 may be made by various processes, including casting, machining from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
A coupling 108 may be used to connect the perf system 100 to other tools. The coupling 108 may be threaded.
A retaining cap 110 may be used to retain the block chamber within the body of the tool. The retaining cap 110 may also create a seal that may prevent the ingress of wellbore fluid or contaminants into the perf system. This seal may be hermetic, and may comprise a gasket, or a polymer that is compressed between the retaining cap 110 and the tool body.
The material used for manufacturing the retaining cap 110 may comprise aluminum, manganese, zinc, or other bronze alloys. Nickel alloys or combinations of, but not limited to nickel with materials such as iron, chromium, copper, or molybdenum. Stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese. Aluminum alloys or combinations of, but not limited to, zinc, copper, or iron. Other materials may also include, but not limited to, iron, titanium, polymers or plastics, carbon fiber, or tin.
The retaining cap 110 may be made by various processes, including casting, machining from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
The block chamber 112 may be configured to enable one, or many, bullets, or projectiles 114, and propellant to be stored within one block chamber 112. The block chamber 112 may be configured such that the individual chambers 113 that the bullets, or projectiles 114, are hermetically sealed to, may be angled or straight. The bullet chambers 113 may be arranged in various ways, such as staggered, side-by-side, oriented at different angles around the block chamber 112 to fire in multiple directions such as, but not limited to, 0 degrees, 90 degrees, 180 degrees, and 270 degrees. The block chamber 112 may also comprise one or more firing pins that may be, but not limited to, electric primers, mechanical, or electric mechanical firing pins. The block chamber 112 may also house one or more boards that may send or receive command signals.
The material used for manufacturing the block chamber 112 may comprise, but is not limited to, aluminum, manganese, zinc, or other bronze alloys, nickel alloys, combinations of nickel with materials such as iron, chromium, copper, or molybdenum. Stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese. Aluminum alloys or combinations of, but not limited to, zinc, copper, or iron. Other materials may also include, but are not limited to, iron, titanium, polymers, plastics, carbon fiber, and tin.
The block chamber 112 may, for example, be cast, machined from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
A bullet, which is one example of a projectile 114 that may be employed by embodiments of the invention, may be configured in different sizes. Example diameters for a projectile 114 may include, but not are limited to, 0.250″ or 0.500″. The bullet may be hermetically sealed into the block chamber 112. The projectiles 114 may or may not be caseless, and may or may not be received within a cartridge.
The bullets, or projectiles 114, may also be manufactured to house, within the bullet or projectile 114, devices and elements such as, tracers, smart technology such as nano technology, that is released from the bullet sometime during impact or after. The bullets, or projectiles 114, may also be a dissolvable material that may dissolve over time after the bullet, or projectile 114, is fired.
The material(s) used for manufacturing the projectile 114 may comprise, for example, aluminum, manganese, zinc, or other bronze alloys, nickel alloys or combinations of, but not limited to nickel with materials such as iron, chromium, copper, or molybdenum, stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese, or aluminum alloys or combinations of, but not limited to, zinc, copper, or iron. Other materials may also include, but are not limited to, iron, titanium, polymers or plastics, carbon fiber, or tin. The projectile 7 may also be made with an alloy material, such as a magnesium-based alloy for example, that dissolves over time.
The projectile 114 may be cast, machined from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
A blank chamber 116 may comprise a blank 117 (see
A coupling 118 may be used to connect the perf system to other tools. The coupling 108 may or may not be a threaded coupling.
The connection sub 120, which may be threaded or comprise a push-to-unlock connection, may enable the perf system to connect to other tools that are downhole of the perf system.
The controls housing 106 may house one or more of PCBs, master control units, CPUs, or modems. The control board, or boards, stored in the controls housing 106 may receive and send data, and control signals, to the perf system 100 or back to the surface during operation. The controls housing 106 may also house, for example, a pressure sensor, temperature, sensors, accelerometers, or an optical device or sensor that may record internal and or external data.
The material used for manufacturing the controls housing 106 may comprise aluminum, manganese, zinc, or other bronze alloys, nickel alloys or combinations of, but not limited to nickel with materials such as iron, chromium, copper, or molybdenum, stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese, aluminum alloys or combinations of, but not limited to, zinc, copper, or iron., and other materials may also include, but not limited to, iron, titanium, polymers or plastics, carbon fiber, or tin.
The controls housing 106 may be cast, machined from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
A seal 122 may be incorporated to protect the system from contamination. The seal 122 may be made from various materials such as, but not limited to, polymers, rubber, or plastics.
A coupling 108 may be used to connect the perf system to other tools. The coupling 108 may or may not be threaded.
The board encloser 124 may house, for example, a remote IO (input/output) interface, or separate control board that may be operable to receive signals from the master control board, and to send signals or commands to the perf system. The control board may comprise multiple signal switches that are wired to their own respective firing pin, or ignition switch. The control board may receive a signal or command from the master control board that may command the perf system to fire one, or more, bullets, or other projectiles. The board may be potted, or protected, with a coating to protect the board from, but not limited to, shock, vibration, contaminants, or high temperature and pressure.
The blank chamber 116 may be configured to hold a blank 117 (see
A block chamber 112 may be configured to accommodate bullets 114, or other projectiles, of various sizes, such as, but not limited to, projectiles having a diameter within a range of about 0.250″ or 0.500.″ The projectile 114 may or may not be hermetically sealed into the block chamber. The projectiles 114 may or may not be caseless, that is, not stored within, or connected to, a cartridge.
The projectiles 114 may also be manufactured to house, or contain, within the projectile 114, components including, but not limited to, tracers, or smart technology such as nano technology, that is released from the projectile 114 sometime during impact or after. The projectiles 114 may also be a dissolvable material, such as but not limited to, magnesium-based alloys that may dissolve over time after the projectile, or projectile, is fired.
The material used for manufacturing the projectile 114 may be, but not limited to aluminum, manganese, zinc, or other bronze alloys, nickel alloys or combinations of, but not limited to nickel with materials such as iron, chromium, copper, or molybdenum, stainless steel alloys or combinations of materials such as, but not limited to, nickel, copper, or manganese, aluminum alloys or combinations of, but not limited to, zinc, copper, or iron, and other materials may also include, but not limited to, iron, titanium, polymers or plastics, carbon fiber, or tin. The projectile 114 may also be made with an alloy material that dissolves over time.
The projectile 114 may be cast, machined from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
The propellant 126 may comprise a source, or substance, that may be ignited and, after ignition, propel the projectile 114. The propellant 126 may comprise, for example, a powder or grain of various sizes that may be made up of potassium nitrate, sulfur, and charcoal. The propellant 7 may also be made of, but not limited to, nitroglycerin, nitrocellulose, nitroguanidine, ammonium nitrate, ammonium dinitramide, or a combination of other highly explosive substances. The substance used in the propellant 126 may also be oxidizable, and may produce various quantities and types of high pressure gas(es) that will propel the projectile 114 out of the block chamber 112. The propellant 126 may be ignited, or activated, by electrical connection, mechanical, or electrical/mechanical connection.
The primer 128 may comprise, for example, a resistance filament that may allow a specified current, at a predetermined voltage, to travel through the primer 128. Passage of the current, which may result from a voltage differential across the filament may cause the propellant 126 to be ignited or activated. The primer 128 may also extend up into the propellant 126 chamber so that the propellant 126 surrounds the primer 128. The primer 128 may be hermetically sealed into the block chamber 112. The seal may be maintained after the perf system 100 fires, ensuring that no leak paths are created past the propellant 126 chamber after firing. The seal may be a metal-to-metal bond, epoxy bond, or ceramic, elastomer or polymer, or glass seal that is between the primer 128 and the block chamber 112. The primer 128 may be installed into the perf system 100 by an interference fit, compression fit, or threaded into the block chamber 112, for example.
The wire and command pathway 130 may be positioned below the primers 128. This arrangement may enable the command wires to travel from the board encloser 124 to the primers. The main backbone cables and commands (see
A, electrical connector 132 may be connected to a board, or boards, that send commands to the perf system 100, or other tools in the assembly. The electrical connector 132 may be threaded into the system, locked, or pinned into the body, or hermetically sealed. The electrical connector 132 may be rated for high temperature and high pressures, such as but not limited to, high pressures up to about 20,000 psi and high temperatures up to about 250 Celsius.
The backbone pathway 134 may enable command wires or cables, or other devices, to travel through the system and enable command access throughout the perf system 100.
A pressure chamber 136 may be filled with an oil, or fluid, and thus act as a pressurization system, and/or for cooling the system down during operation. In this way, the entire perf system 100 may be filled with oil, or another fluid, which may equalize the internal pressure in the perf system 100 relative to the external pressure in an environment such as a well bore, or at least reduce a pressure differential between the two.
A compensator 138 may be a honed, or machined, orifice or cylinder that may be filled with oil, or a fluid, that is pressurized by external pressure acting on a sealed hydraulic puck, or piston. External pressure may enter the pressure chamber 136 and act on a piston so as to cause the piston to move and pressurize the internal body and equalizing the internal pressure in the perf system 100 with the pressure in the wellbore.
An electrical connector 140 may be connected to the backbone and to the board enclosed in the perf system 100 block chamber 112. This electrical connector 140 may enable commands to be sent to other assemblies within the system. The electrical connector 140 may be threaded into the system, locked, or pinned into the body, or hermetically sealed. The electrical connector 140 may be rated for high temperature and high pressures.
Following are some example configurations/deployments of the perf system and associated components: [1] perf system tethered to wireline, collectively denoted at 142—the perf system 100 may be tethered to wireline and pumped down the wellbore with high or low-rate fluid and or be pulled up the wellbore by the tethered wireline connection; [2] plug 144—a plug 144 may be used to seal the wellbore so that fluid is prevented from passing the section of the wellbore that the plug 144 is set in; and [3] wellbore casing 146 or other tubular member—the wellbore casing 146 may be a steel, or alloy, pipe that is installed in the wellbore and cemented in place.
With continued reference to
The tether 102 described in
The controls housing 106 may also hold a pressure sensor, temperature, sensors, accelerometers, or an optical device or sensor that may record internal and or external data.
The material used for manufacturing the controls housing may be, but not limited to aluminum, manganese, zinc, or other bronze alloys. Nickel alloys or combinations of, but not limited to nickel with materials such as iron, chromium, copper, or molybdenum. Stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese. Aluminum alloys or combinations of, but not limited to, zinc, copper, or iron. Other materials may also include, but not limited to, iron, titanium, polymers or plastics, carbon fiber, or tin.
Finally, the controls housing may be made from, but not limited to, cast, machined from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
A tractor 152 may comprise, for example, a mechanical, electrical, or hydraulic driven or propulsion unit used to move different tools or assemblies around in the wellbore. This tractor 152 may be used, for example, to push the perf system around in a downhole environment.
The perf system 100 may be assembled together, possibly releasably, with the tractor 152 and propelled, or moved, around in the wellbore.
A secondary tractor 154 may be assembled downhole of the perf system 100 to pull the perf system 100 around in the wellbore. The system is not limited to how many devices, tools, or tractors that may installed with the assembly. For example, such other devices, tools, and/or tractors, may include, but are not limited to, plugs, slips, gamma ray or other logging tools, downhole scanning systems, and imaging tools.
A plug 144 may be used in some embodiments to seal the wellbore so that fluid and other materials may be prevented from passing into the section of the wellbore that the plug 144 is set in.
The master control board may be preprogrammed with a set of coding and commands which, when executed, may cause performance of any or all of the following operations: [1] navigate the wellbore autonomously to different locations within the wellbore during the frac; [2] perforate the wellbore with the perf system 100 at one or more preprogrammed locations—the locations may be located within the system by an onboard encoder, resolver, or a combination of these; [3] create a seal and hold in place during the frac.
Preparation and placement of the perf system 100 in one or more locations in a downhole environment may comprise the following operations: [1] assemble the perf system 100 with one or more tractors 152/154, and device(s) such as a plug, packer, or other device or tools that may be need during the frac'ing operation; [2] place the perf system 100, and associated assemblies, in the lubricator, and pump the perf system 100 down the well to a predetermined location, or locations, in the casing 146 in the wellbore, or to an area where pumping may no longer force the assembly further down the wellbore—note that pump down may only be needed if the perf system 100 is tethered to a wireline for example—if the perf system 100 is tethered and pumped down the wellbore, once the perf system 100 reaches its predetermined location, it may be mechanically, electrically, or electrically mechanically released from the wireline, or tethered system—on the other hand, if the perf system 100 is not tethered, pumped down, and released, it may self-propel itself from the surface to a predetermined location in the wellbore, and power, which may be supplied by a power source, such as a battery, fuel cell, or nuclear power may be required to power the perf system 100.
The perforation system block diagram of
Each perforation projectile assembly may have a wire, which when connected to a flow of current, AC or DC, may ignite the propellant to fire the projectile. The PDC 158 may receive a specific message from the network communication backbone 160. The first message may fire the safety blank 117. This action may enable subsequent messages to the PDC 158 to fire a single projectile, either in a predefined order, or specific bullet position.
The PDC 158 may be housed in a board enclosure. All bullet chambers 113 may be capped with a sealant, as shown in
With continued reference to
As shown in
A perf system 100 may also comprise a connection device 104. The connection device 104 may comprise a cable head connection which may be coupled to the perf system 100.
A sealing and isolation module 162 may be provided in the perf system 100, and may comprise, for example, a pack or plugging device that may isolate areas of the wellbore to create a pressure differential. The sealing element may be actuated by mechanical, electrical, or hydraulic power.
A hydraulic power unit (HPU) 164 may be provided that may comprise, and house, an accumulator or compensator, multiple hydraulic pumps, and electrical wiring that may transmit power and or commands throughout the tool. The hydraulic pump may actuate the sealing and isolation module, and/or the slips 166. The slips 166 may be used to selectively grab, or otherwise engage, the casing or tubular member in the wellbore. This may enable the perf system 100, and other systems and components, to be held in place in the wellbore while the pressure differential increases across the system. The slips 166 may be actuated by a hydraulic pump, for example.
As noted earlier herein, the perf system 100 may comprise a controls housing 106. The controls housing 106 may house one or more PCBs, master control units, CPUs, or modems. The control stored in the controls housing 106 may receive and send data, or signals, from/to the perf system 100 and/or back to the surface during operation. Further, the controls housing 106 may contain a pressure sensor, temperature, sensors, accelerometers, or an optical device or sensor that may record internal and or external data.
An example embodiment of a perf system 100 may comprise a block chamber 112 system as in the example disclosed in
Finally, a perf system 100 may comprise a sensor sub 168. In an embodiment, the sensor sub 168 may comprise, for example, a pressure sensor, temperature sensor, and accelerometer.
As noted earlier, the perf system of
In an embodiment, the example method may comprise:
The example method described above is not limited by the number of stages, distance traveled between stages, number of perforations created by the perf system 100, or rate of fluid being pumped. The above example method describes low rate frac'ing while maintaining a tethered connection to the surface and having a perforation system, such as the perf system 100 disclosed herein, that is reusable and is not destroyed, damaged, or and does not lose power, throughout, or below, the tool while, or after firing, a projectile 114 to perforate the wellbore.
With reference first to
The material used for manufacturing the perf system body 170 may comprise, but is not limited to aluminum, manganese, zinc, or other bronze alloys, nickel alloys or combinations of, but not limited to nickel with materials such as iron, chromium, copper, or molybdenum, stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese, aluminum alloys or combinations of, but not limited to, zinc, copper, or iron, and other materials such as iron, titanium, polymers or plastics, carbon fiber, or tin. The perf system body 170 may be cast, machined from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
As also disclosed in
Finally, the example perf body 170 of
As noted in the discussion of
The perf system 100 may further include a perf system housing 176. In an embodiment, the perf system housing 176 may comprise a housing chamber that encloses all the components needed to load, fire, and reload projectiles such as bullets. The material used for manufacturing the perf system housing 176 may comprise, but is not limited to aluminum, manganese, zinc, or other bronze alloys, nickel alloys or combinations of nickel with materials such as iron, chromium, copper, or molybdenum, stainless steel alloys or combinations of, but not limited to nickel, copper, or manganese, aluminum alloys or combinations of zinc, copper, or iron, and other materials such as iron, titanium, polymers or plastics, carbon fiber, or tin. Finally, the perf system housing 176 may be cast, machined from solid material, or 3D printed or manufactured through a process such as additive manufacturing.
With reference now to
One of these components is a barrel 172. The barrel 172 may be configured to enable the perf system to fire a projectile 114 at an angle relative to structure(s) such as a well casing. The barrel 172 may have any suitable length. A chamber 113 may also be provided that comprises a mechanical and/or electrical system that may operate on a system of motion devices including gears of any type. The chamber 113 may rotate to allow the bullets to enter the chamber 113, and then rotate again to fire a projectile 114 from the chamber 113.
A swing arm 178 may also be provided that may comprise a link that may connect the chamber 113, firing pin 180, and motion devices together. The link may act to connect the motion devices and the chamber 113 to rotate the chamber 113 into the loading position, and the firing position. The link may also be connected to the firing pin 180. In the motion that may take place once the projectile 114 has entered the chamber 113, the chamber 113 may rotate to the firing position and the link may then pull the firing pin 180 into contact with the primer 128 to cause ignition of the propellant 126, and the firing of the projectile 114. The firing pin 180 may comprise a mechanical device configured and operable to exert a force on the primer 128. The firing pin 180 may be mechanically or electrically actuated.
A loading swivel 182 of the example perf system 100 may comprise a mechanical or electrical system that may operate on a system of motion devices such as gears. The loading swivel 182 may also operate on the same motion device that rotates, or activates, the chamber 113, swing arm 178, and firing pin 180. The loading swivel 182 may have a swivel arm 183 that may be connected to the loading swivel 182 that may force the projectiles 114 located in the magazine 184 into the chamber 113.
The swivel arm 183 of the loading swivel 182 may comprise, for example, a mechanical device, or arm, that may be connected to the loading swivel 182. The swivel arm 183 may be configured and operable to engage the projectiles 114 located in the magazine 184 and assist in forcing the projectile 114 into the chamber 113. The swivel arm 183 may have a device such as a spring that forces the swivel arm 183 back into position after the projectile 114 is chambered. The spring may be connected to the loading swivel 182 and the swivel arm 183.
The projectiles 114, which may comprise bullets, may comprise a caseless design that may have an electric, or mechanical, primer 128 built into the propellant 126 of the projectile 114. The projectile 114 may be configured to any shape, size, weight, or diameter and may comprise a hard material such as steel and/or tungsten for example. The projectiles 114 may be treated, such as with heat treating, and/or chemical treating, for example, to increase projectile hardness.
The magazine 184 may house the projectiles 114. The magazine 184 may not be limited to any particular number of projectiles 114 that it may house at one time, or during operation. The magazine 184 may be loaded into the perf system 100 with one or more projectiles 114 already housed inside. The magazine 184 may comprise a spring 186 that forces the projectiles 114 down the magazine 184 as projectiles 114 are loaded into the chamber 113. The magazine 184 may comprise a lip on the loading end that may prevent the projectiles 114 from continuing to eject from the magazine 184 once a projectile 114 has been loaded into the chamber 113.
With particular reference now to
In a third mode of the perf system 100, disclosed in
In a fifth mode of the perf system, disclosed in
In the sixth, and next to last, mode in this example, the chamber 113 is in the firing position and projectile 114 (P1) is ready to fire. The firing pin may now be triggered to impact the primer and fire the bullet. That is, bullet 1 is in a ready-to-fire position.
In the final mode of this example, the firing pin has impacted the primer and the projectile 114 (P1) has been fired out of the chamber 113 and through the barrel 172. The projectile 114 (P1) will then create a perforation in the casing. The projectile 114 (P1) may not create any debris, and the chamber 113 may be empty of any bullet related materials and debris. The loading swivel 182 and swivel arm 183 are now in position to load the next projectile 114. The rotation created by the motion device will rotate the loading swivel 182 and swivel arm 183 into contact with the next projectile 114 (P2) and the chamber 113 will be reloaded back into the stand-by position.
With attention now to
When the plug has reached the desired location, the plug may then be set in place 210 to seal the wellbore. With the wellbore sealed below the perforation location, a frac process may then be performed 212, using a perf gun such as the perf gun 100 for example, to penetrate the casing so as to create perforations, or other openings, in the casing such that the interior of the casing is in fluid communication with the formation by way of the perforations. Because the perf gun may be reusable, the perf gun may remain downhole, and attached to wireline/tether and communication lines, during performance of the operation 204, and operations thereafter of the method 200.
After the frac is completed, the plug may be unset and proppant flushed past the plug 214. The tool string may then be pulled up hole to the next location in the wellbore 216. Then, the operations 206-214 may be repeated for that location, and for any additional locations in the wellbore where a frac is to be performed, and these processes may be repeated until the well is fully stimulated, or frac'd. Note that, in an embodiment, a single plug may be used for the entire process 200. An embodiment may be such that the plug is reusable, and can be repeatedly set and unset at various locations in the wellbore. Likewise, the perf gun may be used repeatedly in a frac operation until the well is fully stimulated, and may only be returned to the surface when/if reloading of the perf gun with projectiles is needed.
The embodiments disclosed herein (including those in Appendix A hereto) may include the use of a special purpose or general-purpose computer, including various computer hardware or software modules, as discussed in greater detail below. A computer may include a processor and computer storage media carrying instructions that, when executed by the processor and/or caused to be executed by the processor, perform any one or more of the methods disclosed herein, or any part(s) of any method disclosed.
As indicated above, embodiments within the scope of the present invention also include computer storage media, which are physical media for carrying or having computer-executable instructions or data structures stored thereon. Such computer storage media may be any available physical media that may be accessed by a general purpose or special purpose computer.
By way of example, and not limitation, such computer storage media may comprise hardware storage such as solid state disk/device (SSD), RAM, ROM, EEPROM, CD-ROM, flash memory, phase-change memory (“PCM”), or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other hardware storage devices which may be used to store program code in the form of computer-executable instructions or data structures, which may be accessed and executed by a general-purpose or special-purpose computer system to implement the disclosed functionality of the invention. Combinations of the above should also be included within the scope of computer storage media. Such media are also examples of non-transitory storage media, and non-transitory storage media also embraces cloud-based storage systems and structures, although the scope of the invention is not limited to these examples of non-transitory storage media.
Computer-executable instructions comprise, for example, instructions and data which, when executed, cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. As such, some embodiments of the invention may be downloadable to one or more systems or devices, for example, from a website, mesh topology, or other source. As well, the scope of the invention embraces any hardware system or device that comprises an instance of an application that comprises the disclosed executable instructions.
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts disclosed herein are disclosed as example forms of implementing the claims.
As used herein, the term ‘module’ or ‘component’ may refer to software objects or routines that execute on the computing system. The different components, modules, engines, and services described herein may be implemented as objects or processes that execute on the computing system, for example, as separate threads. While the system and methods described herein may be implemented in software, implementations in hardware or a combination of software and hardware are also possible and contemplated. In the present disclosure, a ‘computing entity’ may be any computing system as previously defined herein, or any module or combination of modules running on a computing system.
In at least some instances, a hardware processor is provided that is operable to carry out executable instructions for performing a method or process, such as the methods and processes disclosed herein. The hardware processor may or may not comprise an element of other hardware, such as the computing devices and systems disclosed herein.
In terms of computing environments, embodiments of the invention may be performed in client-server environments, whether network or local environments, or in any other suitable environment. Suitable operating environments for at least some embodiments of the invention include cloud computing environments where one or more of a client, server, or other machine may reside and operate in a cloud environment.
Any one or more of the entities disclosed, or implied, by Figures A-M and/or elsewhere herein, may take the form of, or include, or be implemented on, or hosted by, a physical computing device. Part, or all, of the physical computing device may comprise an element of an ALDA (Axial LiDAR Doppler Analyzer). As well, an ALDA may comprise a physical computing device, as contemplated herein.
Such a physical computing device may include a memory which may include one, some, or all, of random access memory (RAM), non-volatile random access memory (NVRAM), read-only memory (ROM), and persistent memory, one or more hardware processors, non-transitory storage media, UI (user interface) device/port, and data storage. One or more of the memory components of the physical computing device may take the form of solid-state device (SSD) storage. As well, one or more applications may be provided that comprise instructions executable by one or more hardware processors to perform any of the operations, or portions thereof, disclosed herein. Such executable instructions may take various forms including, for example, instructions executable to perform, and/or cause the performance of, any method, process, or portion of these, disclosed herein.
Following are some further example aspects and embodiments of the invention. These are presented only by way of example and are not intended to limit the scope of the invention in any way.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
| Number | Date | Country | |
|---|---|---|---|
| 63363794 | Apr 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18504456 | Nov 2023 | US |
| Child | 18806610 | US | |
| Parent | 18302628 | Apr 2023 | US |
| Child | 18504456 | US |
