U.S. patent application number 11/869201 was filed with the patent office on 2008-10-30 for shape memory materials for downhole tool applications.
This patent application is currently assigned to SCHLUMBERGER TECHNOLOGY CORPORATION. Invention is credited to Yanmei Li.
Application Number | 20080264647 11/869201 |
Document ID | / |
Family ID | 39885626 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080264647 |
Kind Code |
A1 |
Li; Yanmei |
October 30, 2008 |
SHAPE MEMORY MATERIALS FOR DOWNHOLE TOOL APPLICATIONS
Abstract
A technique utilizes shape memory materials in wellbore
applications. Well components are formed with shape memory
materials able to transition to a desired state when activated. The
well components are moved downhole with the shape memory material
in one state. Upon introduction of an activating agent, the
automatic transition of the shape memory material is initiated and
the well component is changed to a state in which it is able to
perform a desired downhole function.
Inventors: |
Li; Yanmei; (Pearland,
TX) |
Correspondence
Address: |
SCHLUMBERGER RESERVOIR COMPLETIONS
14910 AIRLINE ROAD
ROSHARON
TX
77583
US
|
Assignee: |
SCHLUMBERGER TECHNOLOGY
CORPORATION
Sugar Land
TX
|
Family ID: |
39885626 |
Appl. No.: |
11/869201 |
Filed: |
October 9, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60914569 |
Apr 27, 2007 |
|
|
|
Current U.S.
Class: |
166/373 ;
166/118 |
Current CPC
Class: |
E21B 33/10 20130101;
E21B 17/042 20130101; E21B 34/06 20130101; E21B 33/1208
20130101 |
Class at
Publication: |
166/373 ;
166/118 |
International
Class: |
E21B 33/128 20060101
E21B033/128 |
Claims
1. A method of operation in a well, comprising: forming a well
component from a shape memory material; deploying the well
component downhole into a wellbore; and providing an activating
agent downhole to transition the shape memory material so as to
change the shape of the well component.
2. The method as recited in claim 1, wherein forming comprises
manufacturing the shape memory material in a shape; and deforming
the shape memory material to a deformed shape.
3. The method as recited in claim 1, wherein deploying comprises
running the well component downhole with an equipment string.
4. The method as recited in claim 1, wherein providing comprises
providing the activating agent in the form of heat.
5. The method as recited in claim 1, wherein providing comprises
providing the activating agent in the form of moisture.
6. The method as recited in claim 1, wherein providing comprises
providing the activating agent in the form of a change in the pH
value of the environment surrounding the shape memory material.
7. The method as recited in claim 1, wherein providing comprises
providing the activating agent in the form of light.
8. The method as recited in claim 1, wherein providing comprises
providing the activating agent in the form of an electromagnetic
field.
9. The method as recited in claim 1, wherein forming comprises
forming a sealing element.
10. The method as recited in claim 9, wherein forming the sealing
element comprises forming a packer.
11. The method as recited in claim 1, wherein forming the sealing
element comprises forming a threaded region of the well component
from the shape memory material.
12. A well device, comprising: a downhole tool formed at least in
part of a shape memory material, the shape memory material having a
first material property when exposed to a first stimulus and a
second material property when exposed to a second stimulus, wherein
at least one of the first stimulus and the second stimulus may be
applied downhole to transition the shape memory material between
the first and the second material properties.
13. The well device as recited in claim 12, wherein the shape
memory material comprises a polymer.
14. The well device as recited in claim 12, wherein the shape
memory material comprises a metal.
15. The well device as recited in claim 12, wherein the downhole
tool comprises a packer having a sealing element formed of the
shape memory material.
16. The well device as recited in claim 12, wherein the downhole
tool comprises a packer having a threaded engagement region formed
of the shape memory material.
17. The well device as recited in claim 12, wherein the downhole
tool comprises a flow control device formed of the shape memory
material.
18. A well system, comprising: a well device having a sealing
element formed of a shape memory material selectively
transitionable between a non-sealing and a sealing shape within a
wellbore.
19. The well system as recited in claim 18, wherein the well device
comprises a seal device.
20. The well system as recited in claim 18, wherein of the well
device comprises a packer.
21. A method, comprising: preparing a shape memory material in a
first state; combining the shape memory material with well
equipment; deploying the well equipment into a wellbore; and
initiating a change in the shape memory material to a memorized
second state while deployed in the wellbore.
22. The method as recited in claim 21, wherein preparing comprises
preparing the shape memory material as a composite memory material
formed with a metal and a polymer.
23. The method as recited in claim 21, wherein preparing comprises
preparing the shape memory material as a layered shape memory
material.
24. The method as recited in claim 21, wherein preparing comprises
using the shape memory material to form a chevron seal.
25. The method as recited in claim 21, wherein preparing comprises
using the shape memory material to form a seal energizer.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present document is based on and claims priority to U.S.
Provisional Application Ser. No. 60/914,569, filed Apr. 27,
2007.
BACKGROUND
[0002] In many downhole applications, one or more components are
actuated to achieve a desired result. For example, a flow control
valve can be actuated to open or close a fluid flow path.
Similarly, a packer or an expandable sand screen can be actuated to
seal off a desired region of a wellbore. Actuating these and other
devices often requires movement of a component, a change in
component shape, or some other type of conversion that transitions
the component to a desired functional state.
[0003] Depending on a variety of factors, including environment and
well equipment structure, actuation of certain components can be
difficult or time-consuming. For example, mechanical actuation can
require movement of large downhole equipment strings. Similarly,
hydraulic or electrical actuation often requires the routing of
control lines over substantial distances along the wellbore.
SUMMARY
[0004] In general, the present invention provides a method and
system for utilizing shape memory materials in wellbore
applications. Well components requiring actuation are formed of or
combined with shape memory materials able to transition to a
desired state when activated. An activating agent can be utilized
downhole to initiate automatic transition of the shape memory
material to a state in which the well component is able to perform
a desired function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Certain embodiments of the invention will hereafter be
described with reference to the accompanying drawings, wherein like
reference numerals denote like elements, and:
[0006] FIG. 1 is a front elevation view of a well system deployed
in a wellbore, according to an embodiment of the present
invention;
[0007] FIG. 2 is a cross-sectional view of a well component formed
from a shape memory material manufactured in a first memorized
state, according to an embodiment of the present invention;
[0008] FIG. 3 is a cross-sectional view of the well component of
FIG. 2 following deformation into an alternate state, according to
an embodiment of the present invention;
[0009] FIG. 4 is a cross-sectional view of the well component of
FIG. 3 following the use of an activating agent to return the shape
memory material and the well component to the memorized state,
according to an embodiment of the present invention;
[0010] FIG. 5 is a cross-sectional view of a packer comprising
shape memory material and deployed in a wellbore in the deformed
state, according to an embodiment of the present invention;
[0011] FIG. 6 is a cross-sectional view of the packer of FIG. 5
following activation of the shape memory material to the memorized
state, according to an embodiment of the present invention;
[0012] FIG. 7 is a cross-sectional view of another embodiment of a
flow control device comprising shape memory material and deployed
in a wellbore in the deformed state, according to an embodiment of
the present invention;
[0013] FIG. 8 is a cross-sectional view of the flow control device
of FIG. 7 following activation of the shape memory material to the
memorized state, according to an embodiment of the present
invention;
[0014] FIG. 9 is a cross-sectional view of a well component having
a threaded connector comprising shape memory material and deployed
in a wellbore in the deformed state, according to an embodiment of
the present invention;
[0015] FIG. 10 is a cross-sectional view of the well component of
FIG. 9 following activation of the shape memory material to the
memorized state, according to an embodiment of the present
invention;
[0016] FIG. 11 is a cross-sectional view of a seal device
incorporating shape memory material, according to an embodiment of
the present invention; and
[0017] FIG. 12 is a cross-sectional view of another embodiment of a
seal device incorporating shape memory material, according to an
embodiment of the present invention.
DETAILED DESCRIPTION
[0018] In the following description, numerous details are set forth
to provide an understanding of the present invention. However, it
will be understood by those of ordinary skill in the art that the
present invention may be practiced without these details and that
numerous variations or modifications from the described embodiments
may be possible.
[0019] The present invention generally relates to downhole or
wellbore tool applications that utilize shape memory materials. One
or more well components are formed from a shape memory material and
deployed downhole in a wellbore. The shape memory material is
readily transformable from one state to another state and thus can
be selectively transitioned while downhole to perform a desired
function. The change of states can be induced by an appropriate
activating agent.
[0020] Shape memory materials may comprise one or more materials.
For example, shape memory materials can be metallic and/or
polymeric. The metallic type of shape memory material comprises a
shape memory alloy that gains its shape memory effect from a
solid-state phase change, i.e. molecular rearrangement. This type
of phase change is similar to the phase change that occurs in
transitioning from solid to liquid and vice versa in that a
molecular rearrangement occurs, but the molecules remain closely
packed. However, the substance remains in a solid-state. In many
applications, a temperature change around 10.degree. C. is adequate
to initiate a solid-state phase change. Examples of suitable
metallic shape memory materials are nickel-titanium alloys. Other
shape memory materials comprise copper-aluminum-nickel alloys,
copper-zinc-aluminum alloys, and iron-manganese-silicon alloys.
Additionally, composite shape memory materials can be used. For
example, the shape memory material may comprise polymeric shape
memory composites, metal/polymer shape memory materials, e.g. metal
bonded polymer parts, polymer or metal coated/layered shape memory
materials, e.g. rubber coated shape memory polymer parts, and other
composite memory materials.
[0021] The polymeric type of shape memory material often exhibits
radical change from a normal rigid polymer to a very stretchy,
elastic material and back upon input of a proper activating agent.
The change between states can be repeated without substantial
degradation of the material. The "memory" or recovery quality comes
from the stored mechanical energy attained during the
reconfiguration and cooling of the material. Above its transition
temperature, the polymeric shape memory material transitions from a
rigid, plastic state to a flexible, elastic state. When cooled, the
material again becomes rigid and can be constrained in a new shape
configuration. Shape memory characteristics can be engineered into
several polymers, such as epoxy-based polymers, methacrylate
polymers, and stryrene-based polymers.
[0022] Depending on the desired downhole objective, an appropriate
shape memory material can be selected for use in connection with
downhole oilfield applications. Components of downhole well tools
can be made of shape memory materials that undergo a desired change
of state. For example, the shape memory material can be selected to
undergo a change of shape, stiffness, position, or other mechanical
characteristics in response to an appropriate activating agent.
Examples of activating agents comprise application of heat, matter
absorption, UV exposure, electromagnetic field exposure, and other
stimuli.
[0023] Components constructed with shape memory materials can be
used in a variety of equipment types and well applications. For
example, shape memory material can be used in the construction of
packers. In one embodiment, a polymeric shape memory material or
composite shape memory material is used in the formation of the
packer sealing element. The packer element is manufactured in a
desired shape, referred to as the memory or memorized shape with
the selected shape memory material. The component is then heated to
a higher temperature and deformed to a second shape, referred to as
the deformed shape. After cooling, the component, e.g. packer
element, is installed on an appropriate tool string and sent
downhole. Upon heating of the packer element to a certain
temperature, the element returns to the first memorized shape. This
memorized shape can be an expanded shape selected to seal off an
annulus between a tubing and a casing. In this embodiment, heat is
used as the activating agent, and the heat can be obtained from
downhole fluid heating.
[0024] A variety of other well components can be formed from shape
memory material and utilized in downhole applications to perform a
desired function. For example, the shape memory material can be
used to construct a variety of sealing elements that can be used in
inflatable packers, expandable packers, mechanically set packers,
bridge plugs and other sealing devices. The shape memory materials
also can be used in constructing sealing elements on sand screens
and other downhole components. The activating agent supplied can be
in the form of heat, moisture, changing pH, light, or an
electromagnetic field. The components can be un-set or changed back
by changing the corresponding stimuli, e.g. activating agent. For
these types of sealing applications, the seal elements can be made
solely from shape memory material, from composites of elastomer and
shape memory material, e.g. elastomeric membrane supported by a
shape memory material frame, or from other material composites.
[0025] Additional embodiments of well components formed in whole or
in part from shape memory materials comprise flow control valves.
The shape memory material can be used to shut off flow, for
example, between an inner tubing and an annulus space upon
selective activation with an appropriate activating agent. In other
applications, components may be constructed with threaded regions
formed of shape memory material. The threaded region is used to
connect the component with a corresponding component. However, upon
activation, the shape memory material changes shape in a manner
that disengages the threaded region from the corresponding
component. This type of mechanism can be very useful in, for
example, the retrieval of packers. The use of shape memory material
enables avoidance of the conventional practice of cutting apart the
packer body to disengage connected components. When shape memory
material is used, only an appropriate heating source or other
activating agent is necessary to cause the desired disengagement
between connected components.
[0026] Referring generally to FIG. 1, an example of a well system
utilizing one or more well components constructed with shape memory
material is illustrated. In the illustrated embodiment, a well
system 20 comprises a well equipment string 22, e.g. a completion
assembly, deployed in a wellbore 24 via a tubing 26, e.g. coiled
tubing or jointed tubing. The wellbore 24 is drilled into a
geological formation 28 and extends downwardly from a wellhead 30
positioned at a surface 32, such as a seabed floor or a surface of
the earth. The wellbore 24 may be oriented generally vertically or
with combined vertical and deviated sections. Furthermore, the
wellbore 24 may be open or lined with a casing 34 depending on the
specific environment and application. If wellbore 24 is lined with
casing 34, a plurality of perforations 36 are formed through the
casing to accommodate flow of fluid between formation 28 and
wellbore 24.
[0027] In the embodiment illustrated, well equipment string 22
comprises a well component 38 formed from a shape memory material
40. The well component 38 is utilized in wellbore 24 and may be
transitioned between states. For example, the shape memory material
40 enables the transition of well component 3 8 between a first,
e.g. deformed, shape illustrated in solid lines and a second, e.g.
memorized, shape illustrated in dashed lines in FIG. 1. The
transition between two functional states, e.g. shapes, is readily
achievable while the well component is positioned downhole. The
transition can be induced simply by providing or enabling the
appropriate activation agent proximate the shape memory
material.
[0028] One embodiment of well component 3 8 comprises a packer
having a packer sealing element. Referring generally to FIG. 2, a
packer sealing element 42 is illustrated as formed with shape
memory material 40. Packer element 42 is initially manufactured
from shape memory material 40 in the memory or memorized shape
illustrated in FIG. 2. In this example, the memorized shape
comprises an expanded sealing region 44 that extends radially
outward from a base region 46. The expanded sealing region 44 is
formed with sufficient size and shape to seal off the annulus of
wellbore 24. For example, sealing region 44 may be designed to
extend radially outward a sufficient distance to seal against
casing 34.
[0029] Following manufacture of packer element 42 in the expanded,
memorized state, the shape memory material 40 is heated to an
increased temperature and deformed to another shape, as illustrated
in FIG. 3. In this embodiment, the deformed shape may be a radially
constricted shape similar to the tubular shape of base region 46.
When the shape memory material 40 cools, the deformed shape is
retained and the packer element 42 can be moved and manipulated in
this deformed shape. However, upon introduction of the appropriate
activating agent, e.g. sufficient heat, the shape memory material
40 causes packer sealing element 42 to return to its memorized
shape, as illustrated in FIG. 4. In some applications, the shape
memory material can be shifted back and forth between states by
providing appropriate stimuli. For example, the shape memory
material 40 may have a first material property when exposed to a
first stimulus and a second material property, e.g. new shape or
consistency, when exposed to a second stimulus. At least one of the
first stimulus and the second stimulus may be presented downhole to
cause a desired transition in the shape memory material.
[0030] In an actual well application, packer sealing element 42 may
be mounted on a tubing 48 or on another appropriate structure of
well equipment string 22, as illustrated in FIG. 5. The packer
sealing element 42 is mounted to well equipment string 22 in its
deformed state so that it does not interfere with the surrounding
casing 34 (or the wellbore wall in an open wellbore) during
deployment of well equipment string 22 downhole. Once well
equipment string 22 and well component 38 are deployed to a desired
location in wellbore 24, an appropriate activating agent is used to
cause the shape memory material to transition to its memorized
shape. In the embodiment illustrated, this transition results in
the expansion of packer element 42 such that sealing region 44
expands radially outward to seal off the annulus 50 surrounding
tubing 48, as illustrated in FIG. 6.
[0031] The expansion of packer element 42 can be induced by an
activating agent in the form of sufficient heat due to downhole
fluid heating. The heat increases the temperature of the shape
memory material 40 to a level that causes transition to the
memorized/expanded shape. However, the shape memory material also
may be selected so the packer sealing element 42 is caused to
change shape upon the introduction of other activating agents. For
example, the sealing element can be induced to change shape upon
the introduction of sufficient moisture, a specific pH value, light
or a specific type of light, or an electromagnetic field. In some
applications, the shape memory material also can be changed back to
the initial shape by changing corresponding stimuli. It should be
noted that the transition of the sealing component illustrated in
FIGS. 5 and 6 also is representative of the expansion of one or
more sealing elements positioned on a sand screen. In this latter
embodiment, tubing 48 comprises a sand screen on which one or more
sealing elements 42 are mounted.
[0032] An alternate embodiment of well component 38 is illustrated
in FIGS. 7 and 8. In this embodiment, another type of flow control
device is constructed at least in part from shape memory material.
In FIG. 7, the well component 38 is illustrated as a flow control
valve 52 that may be positioned in well equipment string 22 to
control flow between regions in wellbore 24. For example, the flow
control valve 52 can be used in controlling flow between an
interior of a tubing 53 and the surrounding annular space.
[0033] Flow control valve 52 may be formed with a memorized state
that is either open or closed. By way of example, valve 52 is
illustrated in FIG. 7 as deformed to an open state that allows a
flow of fluid 54 to move from a tubing interior 56 to an annulus or
other external region 58. Upon introduction of a suitable
activating agent, e.g. heat, moisture, change in pH value, light or
electromagnetic field, the shape memory material 40 forming flow
control valve 52 transitions to the memorized state, as illustrated
in FIG. 8. In this particular example, the memorized state is one
in which the change in shape memory material 40 blocks the flow of
fluid 54 between interior region 56 and exterior region 58.
[0034] The shape memory material 40 also can be used to construct a
variety of other components in a manner that allows downhole
activation simply through the introduction of a suitable activating
agent. For example, shape memory material 40 may be used to
construct well components 3 8 that may be connected and/or
disconnected upon undergoing a change in state, e.g. a change in
shape.
[0035] As illustrated in FIGS. 9 and 10, for example, a first
component 60 may be connected to a second component 62 by a
suitable engagement region 64, such as a threaded engagement
region. The transition of shape memory material is used either in
forming the connection or in causing disengagement of components
60, 62. Additionally, one or both of the components can be formed
at least in part with the shape memory material 40. In the
embodiment illustrated in FIG. 9, at least a portion of second
component 62 has been constructed with shape memory material 40 in
a manner that allows first component 60 and second component 62 to
be threaded together or otherwise engaged via engagement region 64.
However, second component 62 transitions to a second state, e.g. a
second shape, that causes disengagement of region 64, as
illustrated in FIG. 10. The ability to disconnect components by
inducing a change of state is helpful in a variety of well
equipment applications. For example, this method of disconnecting
is substantially simpler and cheaper than current methods for
disconnecting and retrieving packers from downhole locations. The
packer can be disconnected simply by providing the appropriate
activating agent to cause disconnection of a threaded or otherwise
interlocked engagement region.
[0036] In other applications, the shape memory material 40 can be
used to construct well components 38 that act as sealing devices.
For example, shape memory material 40 may be used to construct well
components 38 that form seals between a variety of component
surfaces in downhole applications. The transition of shape memory
material 40 can be selectively initiated to form a better seal.
[0037] As illustrated in FIG. 11, for example, well component 38
comprises a sealing device 66. In this embodiment, sealing device
66 comprises layers of shape memory material 40 arranged in an
alternating relationship with sealing layers 68. By way of example,
sealing device 66 may be formed as a chevron seal in which layers
of shape memory material 40 and alternating sealing layers 68 are
formed in a generally chevron shape. Upon introduction of an
appropriate activating agent, the layers of shape memory material
40 are transitioned to a second state, such as an expanded shape,
that acts to further squeeze sealing layers 68. Thus, the
alternating layers of shape memory material 40 can be used to
create a seal stack able to exert greater sealing force which, in
turn, facilitates sealing against higher differential
pressures.
[0038] In another embodiment of sealing device 66, shape memory
material 40 is used to create an energized seal, as illustrated in
FIG. 12. In this embodiment, shape memory material 40 is formed in
an arcuate shape as a seal energizer 70 deployed within a seal body
72 formed of a suitable sealing material. By way of example, seal
body 72 may comprise a seal base region 74 from which extends a
pair of sealing lips 76, 78 separated by a gap 80. The sealing lips
76, 78 are designed to form seals with adjacent surfaces, and seal
energizer 70 is deployed within gap 80 between sealing lips 76 and
78. Upon introduction of an appropriate activating agent, the shape
memory material 40 of seal energizer 70 transitions to a second
state in which the arcuate seal energizer 70 expands to bias
sealing lips 76 and 78 in opposed directions. The expansion of seal
energizer 70 effectively energizes sealing device 66 by creating
greater force between sealing lips 76, 78 and their adjacent seal
surfaces, thereby creating a better seat against higher
differential pressures.
[0039] Depending on the specific application and environmental
factors, each of the components formed with shape memory material
40 as described above can be formed from polymeric shape memory
materials, metallic shape memory materials, or composite shape
memory materials. Components formed in whole or in part with
composite shape memory materials can be formed with, for example,
polymeric shape memory composites. In other applications, the
composite component can be formed from metal/polymer shape memory
materials. For example, metal bonded polymeric parts can be used to
form the shape memory material portion of a given component. The
component also can be formed with polymer or metal coated/layered
shape memory materials, such as rubber coated shape memory polymer
components.
[0040] Shape memory material 40 can be incorporated into the
construction of many types of downhole components used in a variety
of well environments. The ability to transition the shape memory
material between two different states enables simple well tool
activation by the provision of an activating agent. Well components
formed of shape memory material can be designed to enable simple
creation of seals or the breakage of previously created seals. Such
components also can be used to control flow between components or
along a wellbore. The shape memory material components also can be
used to mechanically connect, disconnect, activate, deactivate,
shift, pressurize or otherwise control well equipment utilized in a
variety of well related applications.
[0041] Accordingly, although only a few embodiments of the present
invention have been described in detail above, those of ordinary
skill in the art will readily appreciate that many modifications
are possible without materially departing from the teachings of
this invention. Such modifications are intended to be included
within the scope of this invention as defined in the claims.
* * * * *