The present disclosure relates to hydrocarbon well tools and systems, and methods for operating the same, and more specifically well tools, systems, and methods that utilize a component that changes state as a function of temperature.
Subterranean wells (subsea or land based) are typically created by drilling a hole into the earth with a drilling rig. After the hole is drilled, casing sections are inserted into the hole to provide structural integrity to the newly drilled wellbore. Once the well casing is installed, a work string (e.g., an electric wireline, slickline, tubing, coiled tubing, or other conveyance device) that includes tooling may be lowered into the well via the interior of the well casing. The tooling may include perforating guns, sliding sleeves, safety joints, bridge plugs, etc.
One or more perforating guns may be lowered into the well casing until each is adjacent a hydrocarbon producing portion of the formation disposed outside of the well casing. A perforating gun typically includes shaped charges configured to create perforations in the well casing. More specifically, projectiles or jets formed by the explosion of the shaped charges penetrate the well casing to thereby allow formation fluids to flow through the perforations and into a production string.
A typical perforating gun has an electrically actuated detonator which is cooperatively arranged to set off a first explosive device such as a booster charge or a detonating cord. This first explosive device is, in turn, arranged in detonating proximity of one or more second explosive devices such as the aforesaid shaped charges. It is known that premature actuation of perforating guns and/or removal of unfired perforating guns from a well casing can be dangerous.
A common cause of premature actuation of a perforating gun with an electrically actuated detonator involves the application of power to the cable conductors after the gun is connected to a suspension cable but is still at the surface. To minimize such risk, several techniques may be used: delaying the installation of detonators into the gun and/or delaying connection of the gun's electrical leads; maintaining electrical circuits in an open configuration; utilizing pressure-actuated switches that only activate when the gun is exposed to a predetermined well pressure (much higher than ambient); utilizing arming switches; etc. These techniques do not, however, eliminate all risk of a premature actuation.
It should be understood that any or all of the features or embodiments described herein can be used or combined in any combination with each and every other feature or embodiment described herein unless expressly noted otherwise.
According to an aspect of the present disclosure, a tool for use within a subterranean well extending from a wellhead to a subterranean location, wherein the wellhead resides at a first temperature and the subterranean well increases in temperature in a direction from the wellhead to the subterranean location, increasing from the first temperature to a higher second temperature, includes a component including a meltable material. The meltable material is configured to have a solid first state while the meltable material is at the first temperature. The meltable material in the first state has one or more mechanical properties sufficient to avoid mechanical failure of the component and is configured to have a second state when the meltable material is at the second temperature. The meltable material in the second state lacks the one or more mechanical properties necessary to avoid mechanical failure.
In any of the aspects or embodiments described above and herein, the component is configured to change from the solid first state to the second state after a predetermined period of time.
In any of the aspects or embodiments described above and herein, the meltable material includes a eutectic material.
In any of the aspects or embodiments described above and herein, the component is one of a bearing, a shear pin, a shear stud, or a firing pin.
According to another aspect of the present disclosure, a tool for use within a subterranean well extending from a wellhead to a subterranean location, wherein the wellhead resides at a first temperature, and the subterranean well increases in temperature in a direction from the wellhead to the subterranean location, increasing from the first temperature to a higher second temperature, includes a component including a meltable material. The meltable material is configured to have a solid first state while the meltable material is at the first temperature. The meltable material in the solid first state has one or more mechanical properties sufficient to avoid mechanical failure of the component and is configured to have a second state when the meltable material is at the second temperature. The meltable material in the second state lacks the one or more mechanical properties necessary to avoid mechanical failure. The tool further includes a chamber containing the component. The chamber is configured to separate the component from a well environment exterior to the chamber.
In any of the aspects or embodiments described above and herein, the chamber is configured to thermally insulate the component from the well environment exterior to the chamber.
In any of the aspects or embodiments described above and herein, the chamber contains a vacuum environment in an interior of the chamber.
In any of the aspects or embodiments described above and herein, the chamber includes at least one port configured to provide fluid communication between the well environment exterior to the chamber and an interior of the chamber, and at least one sealing device configured to prevent fluid passage through the at least one port. The at least one sealing device is selectively actuable from a closed configuration to an open configuration.
In any of the aspects or embodiments described above and herein, the chamber includes a first sub-chamber and a second sub-chamber separated from one another by a piston configured for translation within the chamber and the at least one port is configured to provide fluid communication between the well environment exterior to the chamber and an interior of the first sub-chamber.
In any of the aspects or embodiments described above and herein, the chamber includes at least one second port configured to provide fluid communication between the well environment exterior to the chamber and an interior of the second sub-chamber, and at least one second sealing device configured to prevent fluid passage through the at least one second port. The at least one second sealing device is selectively actuable from a closed configuration to an open configuration.
In any of the aspects or embodiments described above and herein, the component is disposed within the interior of the first sub-chamber in contact with the piston. In the solid first state the meltable material of the component retains the piston in a fixed position and in the second state the meltable material of the component allows the piston to translate within the chamber.
In any of the aspects or embodiments described above and herein, the tool further includes a second component disposed within the interior of the second sub-chamber in contact with the piston. The second component includes a second meltable material. The second meltable material is configured to have a solid first state while the second meltable material is at the first temperature. The second meltable material in the solid first state has one or more second mechanical properties sufficient to avoid mechanical failure of the second component and is configured to have a second state when the second meltable material is at the second temperature. The second meltable material in the second state lacks the one or more second mechanical properties necessary to avoid mechanical failure.
In any of the aspects or embodiments described above and herein, the meltable material includes a eutectic material.
According to another aspect of the present disclosure, a method of changing a state of a tool disposed within a subterranean well extending from a wellhead to a subterranean location, wherein the wellhead resides at a first temperature, and the subterranean well increases in temperature in a direction from the wellhead to the subterranean location, increasing from the first temperature to a higher second temperature, includes providing a first tool having a first component including a first meltable material. The first meltable material is configured to have a solid first state while the first meltable material is at the first temperature. The first meltable material in the solid first state has one or more mechanical properties sufficient to avoid mechanical failure of the first component and is configured to have a second state when the first meltable material is at the second temperature. The first meltable material in the second state lacks the one or more mechanical properties necessary to avoid mechanical failure. The first component is configured to change from the solid first state to the second state upon exposure to a well environment for a first predetermined period of time. The method further includes exposing the first component to the well environment for the first predetermined period of time.
In any of the aspects or embodiments described above and herein, the method further includes providing a second tool having a second component including a second meltable material. The second meltable material is configured to have a solid first state while the second meltable material is at the first temperature. The second meltable material in the solid first state has one or more second mechanical properties sufficient to avoid mechanical failure of the second component and is configured to have a second state when the second meltable material is at the second temperature. The second meltable material in the second state lacks the one or more second mechanical properties necessary to avoid mechanical failure. The second component is configured to change from the solid first state to the second state upon exposure to the well environment for a second predetermined period of time. The second predetermined period of time is different than the first predetermined period of time. The method further includes exposing the second component to the well environment for the second predetermined period of time.
In any of the aspects or embodiments described above and herein, the first tool includes a chamber containing the first component. The chamber is configured to separate the first component from the well environment exterior to the chamber. The chamber includes at least one port configured to provide fluid communication between the well environment exterior to the chamber and an interior of the chamber, and at least one sealing device configured to prevent fluid passage through the at least one port. The at least one sealing device is selectively actuable from a closed configuration to an open configuration. The method further including actuating the at least one sealing device from the closed configuration to the open configuration.
In any of the aspects or embodiments described above and herein, the first tool has a second component including a second meltable material. The second meltable material is configured to have a solid first state while the second meltable material is at the first temperature. The second meltable material in the solid first state has one or more second mechanical properties sufficient to avoid mechanical failure of the second component and is configured to have a second state when the second meltable material is at the second temperature. The second meltable material in the second state lacks the one or more second mechanical properties necessary to avoid mechanical failure. The second component is configured to change from the solid first state to the second state upon exposure to the well environment for a second predetermined period of time.
In any of the aspects or embodiments described above and herein, the chamber includes a first sub-chamber and a second sub-chamber separated from one another by a piston configured for translation within the chamber and the at least one port is configured to provide fluid communication between the well environment exterior to the chamber and an interior of the first sub-chamber.
In any of the aspects or embodiments described above and herein, the chamber includes at least one second port configured to provide fluid communication between the well environment exterior to the chamber and an interior of the second sub-chamber, and at least one second sealing device is configured to prevent fluid passage through the at least one second port, the at least one second sealing device being selectively actuable from a closed configuration to an open configuration. The first component is located within the first sub-chamber and the second component is located within the second sub-chamber.
In any of the aspects or embodiments described above and herein, the method further includes positioning the first tool adjacent a production zone within a formation disposed outside of the subterranean well.
The present disclosure, and all its aspects, embodiments and advantages associated therewith will become more readily apparent in view of the detailed description provided below, including the accompanying drawings.
The present disclosure relates to subterranean well tooling. The present disclosure is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present disclosure with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein.
A subterranean well has a wellbore that extends into a subterranean formation. The subterranean formation includes one or more production zones. The subterranean well may be land-based, but the present disclosure is not limited thereto. A wellbore includes a well casing and a wellhead. A work string may be used to suspend tooling within the well casing, and to convey the tooling into and out of the well casing. In addition to the tooling, the work string may include tubing, drill pipe, wire line, slick line, or any other known conveyance means. Non-limiting examples of well tooling include perforating guns, sliding sleeves,
According to aspects of the present disclosure, a work string may include at least one tool that includes at least one component comprising a meltable material; e.g., a shear pin, a shear stud, a firing pin, one or more ball bearings, a rupture disk, a dog, etc. The present disclosure may be used with a variety of different tools/tool components, and therefore is not limited to any particular type of tool component. Non-limiting examples of tool components comprising a meltable material are provided below.
As used herein, a “meltable material” refers to a material that melts under a downhole temperature condition. More specifically, a meltable material as used herein refers to a material that is in a solid form when the material is at ambient temperatures (e.g., temperatures up to 110° F./43° C.), and becomes non-solid at temperatures that exist within a wellbore (e.g., temperatures at or greater than 240° F./115° C.). The aforesaid temperatures are exemplary and the present disclosure is not limited thereto. Non-limiting examples of meltable materials include bismuth based low melting alloys and tin based low melting alloys. The present disclosure leverages the fact that wellbores exhibit natural temperature gradients that are either known or can be defined; e.g., temperature gradients that increase linearly at a specific ratio (i.e. 2.8° C./100 m). A tool component residing at an ambient temperature outside the well (e.g., 25° C./77° C.) will begin to increase in temperature as the tool is lowered into the well. The rate at which the tool component increases in temperature may be a function of a number of ascertainable variables; e.g., the temperature of the well at the specific depth at which the tool resides, the configuration of the tool and the position of the tool component within the tool, as well as physical characteristics of the tool component such as the material chemistry, component configuration, material characteristics (e.g., metallurgical characteristics), etc. Many, if not all, of these variables can be determined through testing and/or analysis. As a result, the temperature of a tool component disposed within a well casing for a period of time can be accurately determined.
In some embodiments, a meltable material component may be deployed to prevent motion of other components within a tool; e.g., the meltable material component may be configured as a shear pin or shear stud. The point at which the component fails (thereby permitting other components to be set in motion) may be a function of other variables such as the component's physical configuration (e.g., diameter, etc.), the tensile/yield strength of the meltable material, etc.
According to aspects of the present disclosure, these variables can be ascertained to produce a closely controlled state change (e.g., actuation, arming, etc.) of a tool/tool component via the meltable material component. The change in state refers to a component transforming from a solid having sufficient mechanical properties to avoid failure to a secondary state (e.g., a liquid) wherein the component lacks the mechanical properties necessary to avoid mechanical failure. The tool and/or meltable material tool component may be configured to provide a state change (and in some instances actuation of the tool) after the tool/tool component are disposed within the well at a particular depth for a predetermined period of time. The predetermined period of time may be referred to as a time delay. As will be described below, the configuration of a tool/tool component can be specifically chosen to vary the period of time (i.e., the time delay) that the state change occurs. As a result, under the present disclosure sequential operation of tools within a well can be accomplished.
In some embodiments, the meltable material comprises a eutectic material (e.g., a eutectic alloy). A eutectic material resides in a solid state while it is within a predetermined temperature range but transforms and resides in a liquid state when it is above its eutectic point (i.e., above the aforesaid temperature range). The temperature at which a eutectic material liquefies—which can be defined accurately—is dependent on the composition of the eutectic material. Importantly, the melting point of a eutectic material is also the solidification point of the eutectic material. In other words, a solid body of a eutectic material is immediately converted to a liquid once that body reaches its intrinsic melting point. When two or more of these metals are combined to form a eutectic metal, the eutectic point of the metal is lower than the melting temperature of any of the constituent metals. Non-limiting examples suitable for use as eutectic materials (e.g., eutectic metal alloys or eutectic metallic alloys), include alloys of tin, bismuth, indium, lead, cadmium, or combinations thereof.
The present disclosure is not, however, limited to eutectic-type meltable materials; i.e., non-eutectic meltable materials may be employed alternatively. Non-eutectic materials typically do not have a precise melting point and do not immediately change from a solid state to a liquid state. Non-eutectic materials typically have a moderate range of melting points and their intermediate state may be similar to slush as the material is heated from a lower limit of its melting range to an upper limit of that melting range. Hence, although the present disclosure may include a non-eutectic meltable material, in some applications it may be advantageous to use a eutectic meltable material.
A first non-limiting example of a tool that includes a meltable material component is a perforating gun firing head.
The above non-limiting example illustrates the utility of the present disclosure. In other firing heads, a safety system may utilize shear pins, or shear studs, or other components rather than ball bearings. Under the present disclosure, those components may comprise a meltable material.
Under the present disclosure, in contrast, this type of vent 18 may employ a shear pin 20 comprised of a meltable material, which material possesses sufficient mechanical properties (e.g., tensile/yield strength) when solid to maintain the piston 22 in the vent-closed position. The shear pin 20 is also configured to have a melting point at a predetermined temperature that can be reached after residing within the well environment for a period of time (e.g., a time delay). Once the shear pin 20 changes from a solid having sufficient mechanical properties to maintain the piston 22 in a vent-closed configuration to a secondary state (e.g., a liquid) wherein the shear pin 20 lacks the mechanical properties necessary to maintain the piston 22 position, the piston biasing force causes the piston 22 to move from the vent-closed configuration to a vent-open configuration. Hence, under the present disclosure there is no need to use a drop bar to actuate the vent 18.
The above non-limiting example illustrates the utility of the present disclosure. The present disclosure is not limited thereto. In other vents, a vent may utilize a component other than a shear pin (e.g., a dog, a rupture disk, etc.) comprising a meltable material.
Referring to
In the operation of the firing head embodiment shown in
Referring to
In the operation of the firing head shown in
In a first operation of the firing head shown in
Under certain circumstances, however, it may be desirable to render the firing head 82 (and therefore the perforating gun) into a safe state or an inoperable state. In such an instance, the first sealing device 102 may be left intact, and the sealed thermal insulation surrounding the shear stud 86 therefore left intact. The second sealing device 108 preventing fluid flow through the second port 106 may be selectively actuated from a closed configuration to an open configuration as described above. Once the second sealing device 108 is actuated into an open configuration, high temperature well fluid is allowed to enter the second internal sub-chamber 104. At this point, thermal energy transfer to the firing pin 92 is substantially increased as compared to when the second port 106 was in a closed configuration. After a period of time (which may be accurately determined based on testing and/or analysis), the high temperature well fluid will cause the firing pin 92 to increase in temperature and transform from a solid state to a secondary state (e.g., a liquid) wherein the firing pin 92 lacks the mechanical properties necessary to operate as a firing pin (i.e., to actuate the percussion initiator). As a result, the firing head 82 and therefore the perforating gun is rendered into a safe state and/or an inoperable state and can be safely removed from the well casing.
As stated above, a meltable material tool component may be configured to provide a state change after the tool component is disposed within the well at a particular depth for a predetermined period of time; i.e., a time delay. The configuration of a tool and/or tool component and/or the material properties of a meltable material can be specifically chosen to vary the duration of the time delay. In other words, embodiments of the present disclosure can be configured to provide an accurate time delay. This is particularly true when the meltable material is a eutectic material. The ability of the present disclosure to be configured as a time delay device can provide significant advantages over the prior art. As an example, a work string may include a plurality of perforating guns, separated from one another by distances such that each is designed to operate at a different depth within the well. When a perforating gun is actuated, it is desirable to create an “underbalanced condition” at the site of the perforating gun. The term “underbalanced condition” is used to describe a scenario wherein the formation pressure is greater than wellbore pressure. The greater formation pressure is used to create a fluid surge that cleans debris and thereby increase fluid flow from the formation. In instances wherein a work string includes a plurality of different perforating guns, each of the guns may be located at different depths within the well. The different depths typically have different formation pressures. If several perforating devices are actuated simultaneously, higher pressure fluids entering the well casing from certain well positions (e.g., typically lower positions) may impede fluid flow into the well casing from other well positions (e.g., higher positions). Hence, the desired underbalance condition and fluid flow into the well casing at some locations may be negatively affected. Using the time delay initiation made possible by the present disclosure, however, the perforating gun located at predetermined positions (i.e., those having the lowest formation pressure) can be initiated first. Via time delay, subsequent perforating guns can be actuated in an order that creates a desired sequence. As a result, an improved formation fluid flow into the well casing from a plurality of different zones can be achieved.
The present disclosure includes a plurality of different methods of implementation. For example and using the firing head 26 shown in
As another example, and using the firing head shown in
As another example, a tool string may include a tool string disconnect device such as a safety joint that is configured to permit an operator to disconnect the drill string from another tool (e.g., a packer). During operation, it may be desirable to disconnect the tool string for a variety of reasons, such as but not limited to, a tool string becoming stuck within the well casing. Prior art disconnect devices such as a safety joint may be operated by applying an upstrain on the tool string and rotating the tool string in a predetermined direction a predetermined number of revolutions. In some instances using such a device, it may be difficult to actuate the disconnect device in the manner required to effectuate the disconnect. According to aspects of the present disclosure, a disconnect device may include a disconnect device, such as a safety joint, that includes a component (e.g., a load bearing component) comprising a meltable material. The disconnect device may be configured to contain the component in a chamber that cannot be accessed by well fluid. The chamber may include a port and a sealing device as described above. The port may be selectively actuable from a closed configuration to an open configuration (e.g., via a sealing device) as described above. If the operator elects to disconnect the tool string, the operator causes the sealing device to be actuated into an open configuration. Once the port is opened, high temperature well fluid is allowed to enter the chamber and into contact with the meltable material component. The high temperature well fluid will cause the component to increase in temperature and transform from a solid state to the secondary state. Once the component is transformed to the secondary state, the tool string may be disconnected.
As another example, a tool string may include a bridge plug configured to provide a permanent or temporary seal within a well casing. Prior art bridge plugs may be operated using an electronic signal to a pyrotechnic actuator that actuates the bridge plug from a non-deployed configuration (i.e., no seal) to a deployed configuration (i.e., sealed). Subsequent removal of this type of prior art bridge plug typically requires the bridge plug to be drilled out, which is a time intensive and costly exercise. According to aspects of the present disclosure, a bridge plug may include a component (e.g., a load bearing component) comprising a meltable material. The bridge plug may be configured to contain the component (e.g., a mandrel, etc.) in a chamber that cannot be accessed by well fluid. The chamber may include a port and a sealing device as described above. The port may be selectively actuable from a closed configuration to an open configuration (e.g., via a sealing device) as described above. If the operator elects to remove the bridge plug from the well casing (or otherwise move the bridge plug within the well casing), the operator causes the sealing device to be actuated into an open configuration. Once the port is opened, high temperature well fluid is allowed to enter the chamber and into contact with the meltable material component. The high temperature well fluid will cause the component to increase in temperature and transform from a solid state to the secondary state. Once the component is transformed to the secondary state, the bridge plug may actuate from the deployed configuration (i.e., sealed) to the non-deployed configuration (i.e., no seal). In the non-deployed configuration, the bridge plug may be moved within the well casing.
It is noted that various connections are set forth between elements in the following description and in the drawings (the contents of which are included in this disclosure by way of reference). It is noted that these connections are general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect. A coupling between two or more entities may refer to a direct connection or an indirect connection. An indirect connection may incorporate one or more intervening entities or a space/gap between the entities that are being coupled to one another.
Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
This application claims priority to U.S. Patent Appin. No. 62/884,474, filed Aug. 8, 2019, which is herein incorporated by reference in its entirety.
Number | Date | Country | |
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62884474 | Aug 2019 | US |