Devices, systems, and methods for downhole delivery of one or more wellbore tools in an oil or gas wellbore. More specifically, devices, systems, and methods for improving efficiency of downhole wellbore operations and minimizing debris in the wellbore from such operations.
Hydraulic Fracturing (or, “fracking”) is a commonly-used method for extracting oil and gas from geological formations (i.e., “hydrocarbon formations”) such as shale and tight-rock formations. Fracking typically involves, among other things, drilling a wellbore into a hydrocarbon formation; deploying a perforating gun including shaped explosive charges in the wellbore via a wireline; positioning the perforating gun within the wellbore at a desired area; perforating the wellbore and the hydrocarbon formation by detonating the shaped charges; pumping high hydraulic pressure fracking fluid into the wellbore to force open perforations, cracks, and imperfections in the hydrocarbon formation; delivering a proppant material (such as sand or other hard, granular materials) into the hydrocarbon formation to hold open the perforations and cracks through which hydrocarbons flow out of the hydrocarbon formation; and, collecting the liberated hydrocarbons via the wellbore.
Perforating the wellbore and the hydrocarbon formations is typically done using one more perforating guns. For example, as shown in
Another known perforating gun type is an “exposed” perforating gun 200, as shown in
Gun strings including multiple perforating guns help to improve operational efficiency by allowing multiple perforating intervals to be perforated during one wireline run into the wellbore. The gun string may also include wellbore tools such as one or more fracking plugs (“frac plug”) or bridge plugs, tubing cutters, etc. for downhole operations. For ease of reference in this disclosure, a “gun string” may include any combination of perforating guns and wellbore tools, which further encompasses control devices and the like for use in downhole wellbore operations. Each of the individual perforating guns and/or wellbore tools in the string may have selective detonation/initiation capability. By “selective” what is meant is that a detonator or initiator assembly of an individual perforating gun or wellbore tool is configured to receive one or more specific digital sequence(s), which differs from a digital sequence that might be used to arm and/or detonate another detonator or initiator assembly in a different, adjacent perforating gun or tool. So, detonation of the various perforating guns and/or tools does not necessarily have to occur in a pre-programmed sequence. Any specific perforating gun or tool can be selectively detonated/initiated. The detonation/initiation of perforating guns typically occurs in a bottom-up sequence, i.e., from the perforating gun (or wellbore tool) that is farthest from the wireline to the perforating gun (or wellbore tool) that is nearest, or connected to, the wireline. Thus, in operation, the gun string is lowered or pumped down into the wellbore to a desired location, one or more of the perforating guns and/or tools is detonated/initiated, and the wireline is retracted to the next desired location at which additional perforating gun(s) and/or tool(s) are detonated/initiated. The process repeats until all of the operations have been completed. The wireline cable is then retracted to the surface of the wellbore along with any components that have remained attached to the gun string. Additional debris that remains in the wellbore may need to be recovered as well.
Accordingly, current wellbore operations and system(s) require substantial amounts of onsite personnel and equipment and sometimes result in large residual debris post perforation in the wellbore. Even with selective gun strings, a substantial amount of time, equipment, and labor may be required to deploy the perforating gun or wellbore tool string, position the perforating gun or wellbore tool string at the desired location(s), and remove residual debris post perforating. Further, current perforating devices and systems may be made from materials that remain in the wellbore after detonation of the shaped charges and leave a large amount of debris that must be removed from the wellbore. Accordingly, devices, systems, and methods that may reduce the time, equipment, labor, and debris associated with downhole operations would be beneficial.
In an aspect, an exemplary single-piece, self-contained tethered drone comprises: a body portion; a head portion extending from the body portion and including an integrated electrical and mechanical connecting assembly; a tail portion extending from the body portion in a direction opposite the head portion; a wellbore data collection device housed within the drone and configured for electrically connecting to a wireline; and at least one shaped charge, wherein the tethered drone is formed at least in part from a material that will substantially disintegrate upon detonating the shaped charge, while the wellbore data collection device remains intact and operable for delivering the collected data.
In another aspect, an exemplary single-piece, self-contained tethered drone comprises: a body portion; a head portion extending from the body portion; a tail portion extending from the body portion in a direction opposite the head portion and configured for connecting to a wireline, wherein the tail portion includes an electrical transfer contact and circuitry for receiving an electrical signal from a control unit via the wireline; a detonator and optionally, a detonating cord coupled to the detonator, wherein the circuitry transmits the electrical signal to the detonator; and a plurality of shaped charges received in shaped charge apertures in the body portion, wherein the shaped charge apertures are respectively positioned adjacent to at least one of the detonator and the detonating cord within an interior of the body portion, wherein the tethered drone is formed at least in part from a material that will substantially disintegrate upon detonating the shaped charge.
In a further aspect, an exemplary tethered drone string for downhole delivery of one or more wellbore tools comprises: a first single-piece, self-contained tethered drone connected to a second single-piece, self-contained tethered drone, the first tethered drone and the second tethered drone respectively including a body portion, a head portion, a tail portion, and at least one shaped charge, wherein the head portion of the first tethered drone extends from the body portion of the first tethered drone in a direction towards the second tethered drone and includes an integrated electrical and mechanical connecting assembly, the tail portion of the first tethered drone extends from the body portion of the first tethered drone in a direction opposite the head portion and includes a tail connecting portion, wherein the tail connecting portion of the first tethered drone is configured for at least one of connecting to a wellbore tool and connecting to a wireline, the tail portion of the second tethered drone includes a tail connecting portion, wherein the tail connecting portion of the second tethered drone is electrically and mechanically connected to the integrated electrical and mechanical connecting assembly of the first tethered drone, and the head portion of the first tethered drone, alone, provides an electrical transfer and mechanical coupling between the first tethered drone and the second tethered drone via the integrated electrical and mechanical connecting assembly; and a wellbore data collection device configured for at least one of forming a connection between the first tethered drone and the second tethered drone, forming a connection between at least one of the first tethered drone and the second tethered drone respectively and the wireline, and being housed within at least one of the first tethered drone and the second tethered drone, wherein the first tethered drone and the second tethered drone are formed at least in part from a material that will substantially disintegrate upon detonating the shaped charge, while the wellbore data collection device remains intact and operable for delivering the collected data.
For purposes of this disclosure, a “drone” is a self-contained, autonomous or semi-autonomous vehicle for downhole delivery of a wellbore tool. For purposes of this disclosure and without limitation, “autonomous” means without a physical connection or manual control and “semi-autonomous” means without one of a physical connection or manual control.
A more particular description will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments thereof and are not therefore to be considered to be limiting of its scope, exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
Various features, aspects, and advantages of the embodiments will become more apparent from the following detailed description, along with the accompanying figures in which like numerals represent like components throughout the figures and text. The various described features are not necessarily drawn to scale but are drawn to emphasize specific features relevant to some embodiments.
The headings used herein are for organizational purposes only and are not meant to limit the scope of the description or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.
Reference will now be made in detail to various exemplary embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments.
With reference to
In the exemplary embodiment shown in
In the exemplary disclosed embodiments, the body portion 310 is a unitary structure that may be formed from an injection-molded material. In the same or other embodiments, at least two of the body portion 310, the head portion 320, and the tail portion 330 are integrally formed from an injection-molded material. In other embodiments, the body portion 310, the head portion 320, and the tail portion 330 may constitute modular components or connections.
As shown in
With continuing reference to
The interior 314 of the body portion 310 may have hollow regions and non-hollow regions. As discussed above, the shaped charge apertures 313 receive and retain a portion of the shaped charge 340 in a hollow portion of the interior 314 of the body portion 310. Other regions of the interior 314 may be formed as non-hollow or may include additional internal components of the tethered drone 300 as applications dictate. While the shaped charge apertures 313 (and correspondingly, the shaped charges 340) are shown in a typical helical arrangement about the body portion 310 in the exemplary embodiment shown in
The body portion 310 of the exemplary tethered drone 300 also houses the detonating cord 350 for detonating the shaped charges 340 and relaying ballistic energy along the length of the tethered drone 300. In the exemplary embodiment shown in
In some embodiments, and depending on the arrangement of the shaped charge apertures 313 and shaped charges 340, the detonating cord 350 may be arranged in a complementary manner to ensure that the detonating cord 350 is in sufficient contact or proximity to the shaped charges 340, for detonating the shaped charges 340.
In an aspect, the body portion 310 of the tethered drone 300 also houses a conductive line (not shown) for relaying an electrical signal along the length of the tethered drone 300, as discussed further below. In the exemplary embodiment shown in
The tail connecting portion 370 in the exemplary embodiments includes the detonator 371, an igniter, or an initiator (collectively, “detonator”) 371 for activating the conductive detonating cord 350 upon receiving the selective detonation signal or communicating downline through the electrically conductive cord. A detonator bulkhead seal 372 may substantially isolate the detonator or a relay/transition from the detonator 371 to the detonating cord 350 from exposure to the wellbore fluid, including the associated high temperatures, pressures, and potentially corrosive components.
In an exemplary embodiment, the detonator 371 may be a wireless detonator assembly as shown in
With continuing reference to
In the exemplary wireless detonator assembly 710, a capacitor 717 is positioned or otherwise assembled as part of the electronic circuit board 716. The capacitor 717 is configured to be discharged to initiate the detonator assembly 710 upon receipt of a digital firing sequence via the ignition signal I, the ignition signal being electrically relayed directly through the line-in portion 720 and the line-out portion 722 of the detonator head 718. The fuse head 715 initiates the explosive load 730. In a typical arrangement, a first digital code is transmitted down-hole to and received by the electronic circuit board 716. Once it is confirmed that the first digital code is the correct code for that specific detonator assembly, an electronic gate is closed and the capacitor 717 is charged. Then, as a safety feature, a second digital code is transmitted to and received by the electronic circuit board 716. The second digital code, which is also confirmed as the proper code for the particular detonator, closes a second gate, which in turn discharges the capacitor 717 via the fuse head 715 to initiate the detonation.
The exemplary detonator assembly 710 according to an aspect can be either an electric or an electronic detonator. In an electric detonator, a direct wire from the surface is electrically contactingly connected to the detonator assembly 710 and power is increased to directly initiate the fuse head 715. In an electronic detonator assembly, circuitry of the electronic circuit board 716 within the detonator assembly is used to initiate the fuse head 715.
With reference again now to
The head connecting portion 360 is configured for connecting to and being in electrical contact with a downstream tethered drone or wellbore tool in a tethered drone string 400 as described with respect to
According to an exemplary embodiment, the pin contact 365 of the head connecting portion 360 is configured for being in electrical contact with the electrical transfer contact 371a of the tail connecting portion 370 of an adjacent tethered drone when the head connecting portion 360 is connected to the tail connecting portion 370 of the adjacent tethered drone. The pin contact 365 is configured to transfer the electrical signal from the conductive line or conductive detonating cord 350 to the electrical transfer contact 371a of the tail connecting portion 370 of the adjacent tethered drone such that the electrical signal may be provided to, e.g., the detonator 371 or other component(s) of the adjacent tethered drone and/or a conductive line or conductive detonating cord of the adjacent tethered drone. In an aspect, the pin contact 365 may, among other things, also transfer control information, instructions, data, or power from a control unit 630, wireline 620, and/or battery (not illustrated) to the electrical transfer contact 371a or other onboard computer/circuitry of the tail connecting portion 370 of the adjacent tethered drone. In another aspect, the pin contact 365 may be a spring-loaded pin contact 365 that is biased towards the adjacent tethered drone to maintain electrical contact with the electrical transfer contact 371a of the tail connecting portion 370 of the adjacent tethered drone. The respective electrical transfer contacts of the head connecting portion 360 and the tail connecting portion 370 are not limited according to this disclosure. The respective electrical transfer contacts of the head connecting portion 360 and the tail connecting portion 370 may take any form or configuration consistent with this disclosure—for example, configured for being in electrical contact when the head connecting portion 360 of a first tethered drone 300 is connected to the tail connecting portion 370 of a second tethered drone 300 and for relaying the electrical signal from the conductive detonating cord 350 of the first tethered drone 300 to, e.g., the detonator 371 or other component(s) of the second tethered drone 300.
With continuing reference to
With reference now to
The head connecting portion 420, 421 of each of the first tethered drone 401 and the second tethered drone 402 in the exemplary embodiment shown in
In use, the first tethered drone 401 may be the topmost tethered drone in the tethered drone string 400; i.e., the tethered drone that is connected to the wireline 620 or, for example and without limitation, a wellbore tool, a firing head, an electronic control component, one or more batteries, or the like that is connected between the wireline 620 and the first tethered drone 401. In any such embodiment, an electrical transfer contact of the wireline 620 or other component is configured for being in electrical contact with the electrical transfer contact 471a of the tail connecting portion 470 of the first drone 401. In an aspect, an electrical signal constituting a selective detonation signal may be sent from the control unit 630 at a surface 601 of the wellbore 670 and conveyed via the wireline 620 to the electrical transfer contact 471a of the tail connecting portion 470 of the first tethered drone 401. The selective detonation signal may be configured to activate the detonator 471 of a downstream tethered drone 402 or wellbore tool. Thus, the detonator 471 of the first tethered drone 401 will not be activated by the selective detonation signal. The conductive detonating cord 450 of the first tethered drone 401 will relay the selective detonation signal from the electrical transfer contact 471a of the tail connecting portion 470 of the first tethered drone 401 to the pin contact 365 of the first tethered drone 401. The pin contact 365 of the first tethered drone 401 will transfer the selective detonation signal to the electrical transfer contact 471a of the tail connecting portion 470 of the second tethered drone 402. If the selective detonation signal corresponds to the second tethered drone 402, the detonator 471 of the second tethered drone 402 will activate and ballistically initiate the conductive detonating cord 451 to detonate the shaped charges 441 that the second tethered drone 402 carries. The process will repeat for each tethered drone and/or wellbore tool in the tethered drone string 400. According to the exemplary embodiment of the tethered drone 300, each tethered drone 401, 402 in the drone string 400 may be formed from an injection-molded plastic material that will substantially disintegrate and/or dissolve into a proppant upon detonation of the shaped charges 440, 441, thereby reducing the amount of debris generated by successive detonations of the tethered drones 401, 402.
Notably, the configuration of the tethered drone string 400 and, in particular, the conductive line (for example, in the conductive detonating cord 450, 451 of the exemplary embodiments) allows a single power source, such as a single battery at the top of the tethered drone string 400, to provide power to each tethered drone 401, 402 and/or wellbore tool in the tethered drone string 400. The power may be relayed between each tethered drone 401, 402 and/or wellbore tool via the conductive detonating cords 450, 451 in the same manner as, e.g., the selective detonation signal.
With reference now to
The conductive detonating cord 10 further includes an electrically conductive layer 12. The electrically conductive layer 12 is configured to transfer a communication signal along a length L of the conductive detonating cord 10. The communication signal may be a telemetry signal. According to an aspect, the communication signal includes at least one of a signal to check and count for detonators in a perforating gun string assembly, address and switch to certain detonators, charge capacitors, send a signal to initiate a detonator communicably connected to the conductive detonating cord 10, and various other functions as described in this disclosure. The integration of the electrically conductive layer 12 in the conductive detonating cord 10 helps to omit conductive lines as a separate component.
According to an aspect, the electrically conductive layer 12 extends around the explosive layer 14 in a spaced apart configuration. An insulating layer 18 (
The conductive detonating cord 10 may include a layer of material along its external surface to impart additional strength and protection to the structure of the conductive detonating cord 10.
As illustrated in
According to an aspect, electric pulses, varying or alternating current or constant/direct current may be induced into or retrieved from the electrically conductive layer 12/electrically conductive sheath 13 of the conductive detonating cord 10. The conductive detonating cord 10 includes contacts (not shown) that are configured to input a communication signal at a first end of the conductive detonating cord 10, and output the communication signal at a second end of the conductive detonating cord 10. According to an aspect, the contacts may include a metal, such as aluminum, brass, copper, stainless steel or galvanized steel (including zinc). In order to facilitate the communication of the communication signal, the contacts may at least partially be embedded into the conductive detonating cord 10. The contacts may be coupled to or otherwise secured to the conductive detonating cord 10. According to an aspect, the contacts are crimped onto the detonating cord 10, in such a way that the contacts pierce through the protective outer jacket 16 of the conductive detonating cord 10 to engage the electrically conductive layer 12 or the conductive sheath 13. In use with an exemplary tethered drone 300, the contacts are configured without limitation for being in electrical communication with the electrical transfer contact 371a and the pin contact 365.
With reference now to
With reference now to
The present disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems and/or apparatus substantially developed as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present disclosure after understanding the present disclosure. The present disclosure, in various embodiments, configurations and aspects, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms “a” (or “an”) and “the” refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. Furthermore, references to “one embodiment”, “some embodiments”, “an embodiment” and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as “first,” “second,” “upper,” “lower” etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.
As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur—this distinction is captured by the terms “may” and “may be.”
As used in the claims, the word “comprises” and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, “consisting essentially of” and “consisting of.” Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that variations in these ranges will suggest themselves to a practitioner having ordinary skill in the art and, where not already dedicated to the public, the appended claims should cover those variations.
The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
The foregoing discussion of the present disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the present disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the present disclosure are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects of the present disclosure may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the present disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, the claimed features lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the present disclosure.
Advances in science and technology may make substitutions possible that are not now contemplated by reason of the imprecision of language; these variations should be covered by the appended claims. This written description uses examples to disclose the method, machine and computer-readable medium, including the best mode, and also to enable any person of ordinary skill in the art to practice these, including making and using any devices or systems and performing any incorporated methods. The patentable scope thereof is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if, for example, they have structural elements that do not differ from the literal language of the claims, or if they include structural elements with insubstantial differences from the literal language of the claims.
This application is a national stage application of and claims priority to Patent Cooperation Treaty (PCT) Application No. PCT/M2019/000530 filed Mar. 29, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/690,314 filed Jun. 26, 2018. The entire contents of each application listed above are incorporated herein by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2019/000530 | 3/29/2019 | WO | 00 |
Number | Date | Country | |
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62690314 | Jun 2018 | US |