U.S. patent application number 13/971411 was filed with the patent office on 2015-02-26 for method of using a downhole tool with erosion resistant layer.
This patent application is currently assigned to Thru Tubing Solutions, Inc.. The applicant listed for this patent is Roger Schultz, Brock Watson. Invention is credited to Roger Schultz, Brock Watson.
Application Number | 20150053429 13/971411 |
Document ID | / |
Family ID | 51258298 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150053429 |
Kind Code |
A1 |
Schultz; Roger ; et
al. |
February 26, 2015 |
METHOD OF USING A DOWNHOLE TOOL WITH EROSION RESISTANT LAYER
Abstract
This disclosure is related to downhole tool having an erosion
resistant material metallurgically bonded to portions of the
downhole tool. The downhole tool can have the erosion resistant
material can be disposed on predetermined portions of inner and
outer surfaces of the downhole tool. The disclosure is also related
to a method of using the downhole tool described herein.
Inventors: |
Schultz; Roger; (Ninnekah,
OK) ; Watson; Brock; (Oklahoma City, OK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schultz; Roger
Watson; Brock |
Ninnekah
Oklahoma City |
OK
OK |
US
US |
|
|
Assignee: |
Thru Tubing Solutions, Inc.
Oklahoma City
OK
|
Family ID: |
51258298 |
Appl. No.: |
13/971411 |
Filed: |
August 20, 2013 |
Current U.S.
Class: |
166/387 |
Current CPC
Class: |
E21B 28/00 20130101;
E21B 23/00 20130101; E21B 41/00 20130101; E21B 33/12 20130101; E21B
43/114 20130101; E21B 43/26 20130101; E21B 17/1085 20130101 |
Class at
Publication: |
166/387 |
International
Class: |
E21B 23/00 20060101
E21B023/00 |
Claims
1. A method, the method comprising: providing a perforator tool
into a wellbore, the perforator tool having an erosion resistant
material metallurgically bonded to at least a portion of an outer
surface or an inner surface of the perforator tool wherein the
erosion resistant material shares electrons with the perforator
tool at an interface.
2. The method of claim 1 wherein the erosion resistant material
contains tungsten carbide.
3. The method of claim 1 wherein the erosion resistant material
includes a matrix material to facilitate the bond of the erosion
resistant material onto the perforator tool, the matrix material is
selected from the group consisting of nickel, cobalt, chromium,
tungsten, molybdenum, silicon, iron, carbon, boron, aluminum, and a
combination thereof.
4. The method of claim 1 wherein the perforator tool includes at
least one nozzle assembly and the erosion resistant material is
disposed under, adjacent or atop a portion of the at least one
nozzle assembly.
5. The method of claim 1 wherein at least a portion of an inner
surface of the perforator tool includes a boron containing compound
that is diffused into the inner surface of the perforator tool.
6. The method of claim 1 wherein the perforator tool has at least
one nozzle disposed therein, the at least one nozzle having the
erosion resistant material disposed on an internal portion of the
nozzle.
7. The method of claim 1 wherein the perforator tool has a nozzle
machined in erosion resistant material metallurgically bonded to
sides of an opening in the perforator tool.
8. The method of claim 1 further comprising the step of providing a
vibratory tool into the wellbore with the perforator tool.
9. The method of claim 1 further comprising the step of providing a
packer into the wellbore with the perforator tool.
10. The method of claim 9 further comprising the step of setting
the packer and perforating at one or more locations in the wellbore
and fracturing the one or more locations once the step of
perforating all of the one or more locations is completed.
11. The method of claim 9 further comprising perforating at one or
more locations in the wellbore, then setting the packer and
fracturing the one or more locations once the step of perforating
all of the one or more locations is completed.
12. The method of claim 9 further comprising the step of
positioning the perforator tool and the packer at at least one
location in the wellbore, each positioning step includes setting
the packer, perforating and fracturing the formation at the at
least one location in the wellbore prior to repositioning the
perforator tool and packer to another location.
13. A method, the method comprising: providing a perforator tool
into a wellbore, the perforator tool having an erosion resistant
material diffused into at least a portion of an inner surface of
the perforator tool.
14. The method of claim 13 wherein the perforator tool that
includes at least one nozzle disposed therein, the nozzle having
the erosion resistant material disposed on an internal portion of
the nozzle, the erosion resistant material being a boron containing
compound that is diffused into the inner surface of the downhole
tool and the internal portion of the nozzle.
15. The method of claim 13 wherein at least a portion of an outer
surface of the perforator tool is provided with the erosion
resistant material diffused thereon.
16. The method of claim 13 further comprising the step of providing
a vibratory tool into the wellbore with the perforator tool.
17. The method of claim 13 further comprising the step of providing
a packer into the wellbore with the perforator tool.
18. The method of claim 17 further comprising the step of setting
the packer and perforating at one or more locations in the wellbore
and fracturing the one or more locations once the step of
perforating all of the one or more locations is completed.
19. The method of claim 17 further comprising perforating at one or
more locations in the wellbore, then setting the packer and
fracturing the one or more locations once the step of perforating
all of the one or more locations is completed.
20. The method of claim 17 further comprising the step of
positioning the perforator tool and the packer at at least one
location in the wellbore, each positioning step includes setting
the packer, perforating and fracturing the formation at the at
least one location in the wellbore prior to repositioning the
perforator tool and packer to another location.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a conversion of U.S. Provisional
Application having U.S. Ser. No. 61/759,746, filed Feb. 1, 2013,
which claims the benefit under 35 U.S.C. 119(e). The disclosure of
which is hereby expressly incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a downhole oil and gas tool
having an erosion resistant layer disposed thereon.
[0005] 2. Description of the Related Art
[0006] In standard abrasive perforating operations a hard material
such as sand is typically used as an abrasive media which is mixed
into a liquid slurry and pumped through a workstring from the
surface to a downhole nozzle which creates a high-velocity jet. The
high-velocity jet accelerates the particles in the slurry so that
when they impact a target (such as casing or formation) erosion is
created at the impingement surface. This is often used to create
perforation tunnels through casing and out into the formation to
allow fluid to pumped into the formation (such as fracking), or to
allow hydrocarbon production from the reservoir into the
casing.
[0007] In typical casing perforating operations, the abrasive
material is pumped through the tubing exiting downhole through a
jet and into the annulus between the supply tubular and the casing
or other outer tubular. The high-velocity jet impinges on the
casing ID and erodes a hole in the casing. A portion of the
abrasive slurry from the jet is deflected at various angles back
toward the perforator tool. This deflected fluid often causes
significant erosion on the surface of the perforator tool. This
erosion can severely damage the perforator tool causing the need
for replacement or even failure of the perforator tool.
[0008] During formation fracturing operations the fluid flowing
back from the formation into the wellbore typically carries some of
the proppant (such as sand, ceramic particles, etc.) which was
pumped into the formation during fracturing of the zone. Nearly all
typically used types of proppants are abrasive in nature. When
fluid flows back out of the formation during equalization of the
formation after pressure is reduced after fracturing, the proppant
often impacts the perforating tool with high velocity causing
erosive damage. This damage can be very severe sometimes even
cutting the perforator tool in half.
[0009] Accordingly, there is a need for a perforator that can
withstand erosion during perforating and fracking operations.
SUMMARY OF THE INVENTION
[0010] The present disclosure is directed to a downhole tool having
an erosion resistant material that is metallurgically bonded to the
downhole tool. The present disclosure is also directed to a method
for providing the downhole tool and metallurgically bonding an
erosion resistant material to the downhole tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a cross-sectional view of a perforator tool
constructed in accordance with the present disclosure.
[0012] FIG. 2 is a cross-sectional view of another downhole tool
constructed in accordance with the present disclosure.
[0013] FIG. 3 is a cross-sectional view of one embodiment of a
portion of the perforator tool constructed in accordance with the
present disclosure.
[0014] FIG. 4 is a cross-sectional view of another embodiment of a
portion of the perforator tool constructed in accordance with the
present disclosure.
[0015] FIG. 5 is a cross-sectional view of yet another embodiment
of a portion of the perforator tool constructed in accordance with
the present disclosure.
[0016] FIG. 6 is a cross-sectional view of another embodiment of a
portion of the perforator tool constructed in accordance with the
present disclosure.
[0017] FIGS. 7A and 7B are cross-sectional views of other
embodiments of a portion of the perforator tool constructed in
accordance with the present disclosure.
[0018] FIG. 8 is a cross-sectional view of yet another embodiment
of a portion of the perforator tool constructed in accordance with
the present disclosure.
[0019] FIG. 9 is a side elevation view of one embodiment of the
present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present disclosure, as shown in FIG. 1, relates to a
perforator tool 10 with an erosion resistant material 12 disposed
thereon. The present disclosure also relates to a method of using
the perforator tool 10. The erosion resistant material 12 can be
metallurgically bonded thereon to mitigate the effect of erosion
experienced in oil and gas operations. Examples of erosion
experienced during oil and gas operations include perforation
"splash-back" and formation fracturing "flow-back" damage. The
disclosure also relates to a method of manufacturing the perforator
tool 10. It should be understood and appreciated that the erosion
resistant material 12 can be metallurgically bonded to any downhole
tool that is subject to erosion or is used in operations where the
tool may be subject to perforation "splash-back" and/or "flow-back"
during formation fracturing operations. FIG. 2 provides an example
of another downhole tool, such as a blast joint 11, that can have
the erosion resistant material 12 metallurgically bonded thereon.
In another embodiment of the present disclosure, the perforator
tool 10 can be used in conjunction with a packer 13. The packer 13
can be any type of packer known by one of ordinary skill in the
art.
[0021] A metallurgical bond between two materials causes a sharing
of electrons at an interface of the two materials, which produces a
bond on the atomic level. No intermediate layers such as adhesives
or braze metal are involved, nor are any fastening devices used to
hold the erosion resistant material in place, such as pins, screws
or the like. Erosion resistant materials 12 are typically very hard
materials and can be metallurgically bonded to the perforator tool
10 via any method known to one of ordinary skill in the art.
Examples of methods or processes used to metallurgically bond
materials together include, but are not limited to, Laser Cladding
and Plasma Transferred Arc (PTA).
[0022] The erosion resistant material 12 can be any material known
in the art capable of withstanding erosion conditions experienced
by downhole tools in oil and gas operations. In one embodiment, the
erosion resistant material 12 contains tungsten carbide. The
erosion resistant material 12 can also contain a matrix material to
facilitate the metallurgical bond. Examples of matrix materials
include, but are not limited to, nickel, cobalt, chromium,
tungsten, molybdenum, silicon, iron, carbon, boron, aluminum, or a
combination thereof.
[0023] FIG. 1 shows the perforator tool 10 which includes an outer
surface 14 and an inner surface 16. In one embodiment, a layer of
erosion resistant material 12 is metallurgically bonded to
substantially all of the outer surface 14 of the perforator tool
10. In another embodiment, the perforator tool 10 can include a
layer of erosion resistant material 12 metallurgically bonded to
the inner surface 16 of the perforator tool 10 to mitigate internal
erosion of the perforator tool 10. The erosion resistant material
12 can be provided on the perforator tool 10 in any amounts so that
a predetermined depth (or thickness) of the erosion resistant
material 12 is provided. The predetermined depth of the erosion
resistant material 12 can be in a range of from about 0.005 inches
to about 0.25 inches. In another embodiment, the predetermined
depth of the erosion resistant material 12 can be in a range of
from about 0.08 inches to about 0.16 inches. In yet another
embodiment, the predetermined depth of the erosion resistant
material 12 can be about 0.12 inches. It should be understood and
appreciated that the depth of the erosion resistant material 12 on
the perforator tool 10 can vary depending on where on the
perforator tool 10 the erosion resistant material 12 is disposed.
In these embodiments, the coverage and depth of the erosion
resistant material 12 on the perforator tool 10 is only limited by
the specific functionality of the tool. For example, the perforator
tool 10 still has to be able to connect to other tools in a tool
string, fluid still has to flow through the perforator, fluid still
has to be able to flow out of perforator nozzles if the perforator
tool 10 is equipped with nozzles, etc.
[0024] In yet another embodiment of the present disclosure, the
erosion resistant material 12 is only disposed on predetermined
areas of the perforator tool 10 where the tool 10 is more likely to
be exposed to erosion. For example, the predetermined areas could
be disposed around a nozzle (when perforating with nozzles) or in
areas where tools experience a lot of flow back from fracturing
operations.
[0025] As described herein, the perforator tool 10 can include
nozzles for use in perforation applications. The area around the
nozzles is extremely susceptible to perforation "splash back." In
one embodiment, the perforator includes a nozzle assembly 18 for
directing (or jetting) an abrasive fluid from inside the perforator
tool 10 to outside the perforator tool 10 toward the casing and/or
formation. The nozzle assembly 18 can be constructed of various
elements known in the art for constructing nozzle assemblies 18,
such as shoulder elements 20, sealing rings 22, nozzles 24,
threaded portions, etc. FIGS. 3-5 show various embodiments of how
the erosion resistant material 12 can be disposed on the perforator
tool 10 relative to the nozzle assembly 18. It should be understood
and appreciated that the nozzle assembly 18 can include only a
nozzle 24.
[0026] The embodiment disclosed in FIG. 3 shows the erosion
resistant material 12 disposed on the outer surface 14 of the
perforator tool 10 under a portion of the nozzle assembly 18. In a
further embodiment, the erosion resistant material 12 is disposed
on the outer surface 14 of the perforator tool 10 under the
shoulder element 20 of the nozzle assembly 18. It should be
understood and appreciated that the erosion resistant material 12
can be metallurgically bonded to the outer surface 14 of the
perforator tool 10 prior to adding any element of the nozzle
assembly 18. In another embodiment, the erosion resistant material
12 can be machined or treated to provide an appropriate surface
(e.g., flat and/or smooth) for the support of the nozzle assembly
18.
[0027] The embodiment disclosed in FIG. 4 shows the erosion
resistant material 12 disposed on the outer surface 14 of the
perforator tool 10 adjacent to the nozzle assembly 18. In one
embodiment, the erosion resistant material 12 is metallurgically
bonded to the outer surface 14 of the perforator tool 10 and an
area of the erosion resistant material 12 is removed to permit the
nozzle assembly 18 to be mounted to the perforator tool 10 and be
adjacent to the layer of erosion resistant material 12. In another
embodiment, a machinable plug can be placed to reserve the place of
the nozzle assembly 18 on the perforator tool 10. The erosion
resistant material 12 can then be metallurgically bonded to the
outer surface 14 of the perforator tool 10. Once the erosion
resistant material 12 is metallurgically bonded to the outer
surface 14 of the perforator tool 10, the machinable plug is
removed and the nozzle assembly 18 can then be set in the
perforator tool 10.
[0028] The embodiment disclosed in FIG. 5 shows the erosion
resistant material 12 disposed on the outer surface 14 of the
perforator tool 10 and a portion of the nozzle assembly 18. In a
further embodiment, the erosion resistant material 12 is disposed
on the outer surface 14 of the perforator tool 10 and over the
shoulder element 20 of the nozzle assembly 18. In one embodiment,
the erosion resistant material 12 is applied to the perforator tool
10 after the nozzle assembly 18 is installed in the perforator tool
10. In another embodiment, a machinable plug can be placed to
reserve the place of the nozzle assembly 18 on the perforator tool
10. The erosion resistant material 12 can then be metallurgically
bonded to the outer surface 14 of the perforator tool 10. Once the
erosion resistant material 12 is metallurgically bonded to the
outer surface 14 of the perforator tool 10, the machinable plug is
removed and the nozzle assembly 18 can then be set in the
perforator tool 10. After the nozzle assembly 18 is set in the
perforator tool 10, erosion resistant material 12 can be
metallurgically bonded over a portion of the nozzle assembly
18.
[0029] In another embodiment, the layer of erosion resistant
material 12 metallurgically bonded to substantially all of the
inner surface 16 of the perforator tool 10 to mitigate internal
erosion (or washing) of the perforator tool 10. In a further
embodiment, the layer of erosion resistant material 12 can be
disposed on the inner surface 16 of the perforator tool 10 at only
preselected locations where more erosion is experienced. In yet
another embodiment, the preselected locations where the erosion
resistant material 12 is disposed on the inner surface 16 of the
perforator tool 10 can be areas within a predetermined proximity to
the nozzles 24.
[0030] In yet another embodiment of the present disclosure, the
inner surface 16 of the perforator tool 10 can be provided with the
erosion resistant material 12 via a boriding process, which causes
boron containing compounds to be diffused into the inner surface 16
of the perforator tool 10. The boriding process permits the boron
containing compounds to be diffused into the perforator tool 10 to
create an extremely hard layer that can be thousandths of an inch
thick. In one embodiment, the boron containing compound can be
applied to the inner surface 16 of the perforator tool 10 as a
powder or paste. Once the boron containing power or paste is
applied to the inner surface 16 at the desired locations, the
perforator tool 10 can then be heated for a predetermined amount of
time at a predetermined temperature. It should be understood and
appreciated that the entire perforator tool 10 can be
boronized.
[0031] In another embodiment of the present disclosure shown in
FIG. 6, the nozzle 24 (or integral port) can be machined directly
into the perforator tool 10. In this embodiment it is not necessary
to have a nozzle assembly that is threaded, secured or attached to
the perforator tool 10. In this case there would be no additional
nozzle components. The nozzle 24 can be machined in the perforator
tool by any method known in art. For example, the nozzle 24 can be
machined by accessing the nozzle 24 via an access port 26 disposed
in the perforator tool 10. The access port 26 can be plugged once
machining of at least a portion of the nozzle 24 is completed. In
another embodiment, an internal portion 28 of the nozzle 24 can be
coated with the erosion resistant material 12. The erosion
resistant material 12 can either be metallurgically bonded or
coated via the boriding process described herein.
[0032] In yet another embodiment of the present disclosure and
depicted in FIGS. 7A, 7B, and 8, the perforator tool 10 can have an
opening 30 disposed therein. FIGS. 7A and 7B show the opening 30 in
the perforator tool 10 filled with a metallurgically bonded
material as described herein. FIG. 7A shows the opening 30
completely filled with the metallurgically bonded material and FIG.
7B shows the opening 30 partially filled with the metallurgically
bonded material. FIG. 8 shows the metallurgically bonded material
in the opening 30 having a nozzle 24 disposed directly into the
metallurgically bonded material.
[0033] The present disclosure is also directed to a method of using
the perforator tool 10 as described herein. In one embodiment
depicted in FIG. 9, the perforator tool 10 as described herein can
be run into a wellbore 32 as part of a bottom hole assembly (BHA)
34. The BHA 34 can include any device known in the art for use in a
BHA, such as drilling motor, CT Connector, flapper valve, jar,
hydraulic disconnect, LWD, MWD, etc. The perforator tool 10 can be
run into cased or uncased wellbores to create perforations at a
first location in the casing and/or formation. Once the perforation
has been done the formation can be fractured at the perforations
created at the first location and to facilitate the removal and
collection of hyrdrocarbons from the formation. In a further
embodiment, the perforator tool 10 can be moved to a second
location in the wellbore to perform further perforating of the
casing and/or formation. Another fracturing operation can be done
to fracture the formation at the perforations created at the second
location and facilitate the removal of hydrocarbons from the second
location. It should be understood that multiple locations can be
perforated and fractured during one trip of the BHA 34 (and thus
the perforator tool 10) into the well. It should also be understood
that multiple locations can be perforated and then a single
fracturing operation could be done to fracture perforations in the
multiple locations. In a further embodiment, the perforator tool 10
is run into the wellbore with a packer 36. The packer 36 helps
facilitate the perforating and fracturing of the multiple locations
and/or zones of the formation with one trip of the BHA. In yet
another embodiment of the present disclosure, a vibratory tool 38
can be included in the BHA 34 to facilitate the movement and
positioning of the perforator tool 10 and the BHA 34 in the
wellbore 32. The vibratory tool 38 can be any type of vibration
causing device known in the art for use in a wellbore.
[0034] From the above description, it is clear that the present
disclosure is well adapted to carry out the objectives and to
attain the advantages mentioned herein as well as those inherent in
the disclosure. While presently preferred embodiments have been
described herein, it will be understood that numerous changes may
be made which will readily suggest themselves to those skilled in
the art and which are accomplished within the spirit of the
disclosure and claims.
* * * * *