U.S. patent application number 14/120684 was filed with the patent office on 2015-12-17 for materials with nanomaterials for well operations.
The applicant listed for this patent is Guy L. McClung, III. Invention is credited to Guy L. McClung, III.
Application Number | 20150361760 14/120684 |
Document ID | / |
Family ID | 45971985 |
Filed Date | 2015-12-17 |
United States Patent
Application |
20150361760 |
Kind Code |
A1 |
McClung, III; Guy L. |
December 17, 2015 |
Materials with nanomaterials for well operations
Abstract
Wellbore materials with nanomaterial therein, e.g., cements,
polymers, composites, shape memory material, swellable material,
and epoxies, and systems and methods using such materials, which,
in certain aspects, are methods for cementing casing in a wellbore
with such cement; the material being heatable material in some
aspects, and being one or a combination of electrically resistively
heatable material, microwave heatable material, and/or material
heatable by the application thereto of a magnetic field. This
abstract is provided to comply with the rules requiring an abstract
which will allow a searcher or other reader to quickly ascertain
the subject matter of the technical disclosure and is submitted
with the understanding that it will not be used to interpret or
limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).
Inventors: |
McClung, III; Guy L.; (San
Antonio, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
McClung, III; Guy L. |
San Antonio |
TX |
US |
|
|
Family ID: |
45971985 |
Appl. No.: |
14/120684 |
Filed: |
June 16, 2014 |
Current U.S.
Class: |
166/293 ;
507/200 |
Current CPC
Class: |
C04B 40/0209 20130101;
H05B 6/106 20130101; C04B 2111/94 20130101; C09K 8/467 20130101;
C04B 40/0209 20130101; H05B 6/6491 20130101; E21B 36/00 20130101;
E21B 33/14 20130101; H05B 2214/04 20130101; E21B 36/04 20130101;
C04B 20/0008 20130101; C09K 2208/10 20130101; C04B 28/02 20130101;
C09K 8/42 20130101 |
International
Class: |
E21B 33/14 20060101
E21B033/14; C09K 8/42 20060101 C09K008/42; E21B 36/00 20060101
E21B036/00 |
Claims
1.-109. (canceled)
110. A method comprising making a wellbore in the earth, placing a
tubular string in the wellbore, introducing primary material into a
space between an exterior of the tubular string and an interior of
the wellbore, the primary material containing heatable material,
allowing the primary material to solidify, facilitating solidifying
of the primary material with heat, the heat generated by applying
energy to the heatable material thereby heating the heatable
material, wherein the heatable material is one of or a combination
of electrically resistively heatable material, microwave heatable
material, magnetically heatable material, inductively heatable
material, nanotubes, nanographene, nanographene ribbons,
transformed nanomaterials, carbon nanomaterials, electrically
conductive nanotubes, carbon nanotubes, single-walled nanotubes,
multi-walled nanotubes, double walled nanotubes, and
surface-modified nanotubes.
111. The method of claim 110 wherein solidifying of the primary
material is one of hardening, setting, and curing.
112. The method of claim 110 wherein the primary material is
cement.
113. The method of claim 110 wherein the primary material is one of
epoxy, two-part epoxy, and epoxy system.
114. The method of claim 110 further comprising after the primary
material has solidified, re-heating the heatable material to again
heat the primary material to heat other material adjacent the
primary material.
115. The method of claim 114 wherein the primary material includes
a plurality of spaced-apart portions, the method further comprising
selectively heating each portion.
116. The method of claim 110 wherein the primary material includes
a plurality of spaced-apart portions each of which is heated
according to a program which is one of: simultaneously heating all
portions; selectively heating a portion or portions; sequentially
heating the portions from top to bottom of the wellbore; and
sequentially heating the portions from bottom to top of the
wellbore.
117. The method of claim 110 wherein the heatable material is
heated by an energy source, the method further comprising heating
the heatable material by applying energy to the heatable material
the energy source which is one of: power generator; magnetic field
apparatus; magnetic field generator; induction coil apparatus;
microwave apparatus; microwave generator; a power source at an
earth surface; a power source within earth; a power source within
the wellbore; a power source within the tubular string; and wherein
the tubular string is casing a power source within the casing.
118. The method of claim 110 wherein the primary material is
swellable material, the method further comprising swelling the
swellable material by heating the swellable material by heating the
heatable material.
119. The method of claim 118 wherein the heatable material is
nanomaterial.
120. The method of claim 118 wherein the swellable material has
nanomaterial therein.
121. The method of claim 118 wherein the swellable material has
coating material thereon, the coating material containing
nanomaterial.
122. The method of claim 110 wherein the primary material is shape
memory material with nanomaterial therein, thereon, or both.
123. A method for applying heat to material useful in wellbore
operations, the material in a wellbore or material that is to be
introduced into or used within a wellbore, the material to be
heated containing secondary material, the secondary material being
one of or a combination of resistively heatable electrically
conductive material, resistively heatable nanomaterial, inductively
heatable material, inductively heatable nanomaterial, microwave
heatable material, microwave heatable nanomaterial, and carbon
nanomaterial; the method including heating the material useful in
wellbore operations by heating the secondary material, said heating
of the secondary material done by using apparatus for applying to
the secondary material energy to effect heating, the apparatus
corresponding to the material, the apparatus being one of power
source for applying electric current to the secondary material,
magnetic apparatus for applying a magnetic field to the secondary
material, and microwave apparatus for applying microwaves to the
secondary material; and the heating of the secondary material
facilitating one of hardening, setting, and curing of the material
useful in wellbore operations.
124. The method of claim 123 further comprising heating the
secondary material above ground, within a wellbore, within a
structure downhole, or within a structure above ground.
125. The method of claim 123 wherein the material useful in
wellbore operations is one of shape memory material and swellable
material.
126. A material with nanomaterial therein, the material comprising
one or a combination of shape memory material and swellable
material, the material comprising sufficient nanomaterial dispersed
in the material to effect at least one of: strengthening the
material for use in a wellbore, increasing thermal conductivity of
the material; rendering the material signal-conductive; and
rendering the material electrically conductive; the nanomaterial
present as 0.1 weight percent to 10 weight percent of the
material.
127. The material of claim 126 wherein the nanomaterial is one or a
combination of nanotubes, nanographene, nanographene ribbons,
transformed nanomaterials, carbon nanomaterials, electrically
conductive nanotubes, carbon nanotubes, single-walled nanotubes,
multi-walled nanotubes, double walled nanotubes, and
surface-modified nanotubes.
128. The material of claim 126 wherein the material is in pieces,
the material further comprising a coating on pieces of the
material, the coating containing nanomaterial.
129. The material of claim 126 wherein the pieces have an outer
surface and the coating covers one of: less than all of the outer
surface; all of the outer surface; or spaced-apart discrete amounts
of the outer surface.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application and invention claim, under the
Patent Laws, priority from and under pending U.S. application Ser.
No. 13/317,633 filed Oct. 24, 2011 and under and from U.S.
Application Ser. No. 61/455,705 filed Oct. 25, 2010 and 61/516,589
filed Apr. 5, 2011--all said applications incorporated fully herein
for all purposes. The present application is a Continuation-In-Part
of pending U.S. application Ser. No. 13/317,633.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention is directed to: wellbore operations;
wellbore cement; wellbore cementing methods; methods for casing a
well; methods for producing a well; such methods employing heatable
cement; such methods having cement with resistively heatable
electrically conductive material and/or inductively heatable
material and/or microwave heatable material; swellable material;
shape memory material; in certain particular aspects, to providing
a wellbore with a casing string having all or a portion thereof
cemented with cement having electrically conductive nanomaterial
therein that is heatable by imposing an electric current thereon
thereby heating the cement; and to methods for wellbore operations
using material with nanomaterial therein (e.g., cements, polymers,
composites, swellable materials, shape memory materials, and/or
epoxy systems), and to operations with such materials having
resistively heatable electrically conductive material and/or
inductively heatable material and/or microwave heatable material to
facilitate heating, hardening, setting, and/or curing.
[0003] There are a multitude of known systems and methods for
completing a wellbore for oil and gas production, including many
known casing methods and methods for cementing casing in a
wellbore. There are many known cements used in such systems and
methods.
[0004] FIG. 1 shows schematically and not to scale a typical cased
wellbore with casing cemented in place in the wellbore with cement.
The casing extends from an earth surface down to the bottom of the
wellbore and the casing is usually cemented along its length.
[0005] There have long been needs, recognized by the present
inventor, for heatable cement for wellbore operations, for
effective well completion methods and systems, and for enhanced
methods and systems for producing fluids from a wellbore.
SUMMARY OF THE PRESENT INVENTION
[0006] The present invention discloses swellable materials, shape
memory materials, and cements with nanomaterial therein; and
methods for using such materials in wellbore operations. In certain
aspect, using such cements for cementing casing in a wellbore, the
methods include cementing at least a portion of a casing in a
wellbore with cement that contains one or a combination of:
resistively heatable electrically conductive material; inductively
heatable material; microwave heatable material; and/or electrically
conductive nanomaterial.
[0007] The present invention discloses cements and methods for
using such cements for cementing casing in a wellbore, the methods
including cementing at least a portion of a casing in a wellbore
with cement that contains electrically conductive nanomaterial. In
certain aspects, the present invention discloses materials,
systems, and methods for facilitating the hardening, setting,
and/or curing of material within a wellbore (e.g., but not limited
to, polymers, composites, epoxy systems, and cements) and/or within
a wellbore structure (downhole or above ground) by employing
material that contains one or a combination of: resistively
heatable electrically conductive material; inductively heatable
material; microwave heatable material; and/or electrically
conductive nanomaterial.
[0008] The present invention, in certain aspects, discloses a cased
cemented wellbore and methods for making such a wellbore that has
at least a part of, parts of, or all of the cement containing
electrically conductive nanomaterial therein so that part, parts,
or all of the cement is heatable by imposing an electric current on
the electrically conductive nanomaterial resulting in resistive
heating of the cement, and, if desired, things in contact with or
near the cement. The current may be either alternating current or
direct current. Such heating may also facilitate curing,
solidifying, and/or setting of the cement. In one aspect, material
(e.g., shape memory material, swellable material, cement, polymer,
composite, epoxy system) according to the present invention has
nanomaterials therein for strengthening, and/or for electrical
conductivity and/or for signal conductivity, which are in certain
aspects electrically conductive, for example, and not limited to,
electrically conductive nanotubes, nanographene, nanographene
ribbons, and/or transformed nanomaterials and carbon nanomaterials,
e.g., but not limited to, carbon nanotubes. Nanomaterial and/or
electrically conductive nanomaterial in embodiments of the present
invention may include one or a variety of nanotubes, including, but
not limited to single-walled nanotubes, multi-walled nanotubes,
double walled nanotubes, and/or surface-modified nanotubes.
"Nanomaterial" includes, without limitation, one, some or any
combination of these materials and/or nanotubes.
[0009] It is within the scope of the present invention to impose a
magnetic field on inductively heatble material, to impose an
electric current on electrically conductive material, and/or to
impose an electrical current on electrically conductive
nanomaterial in material (e.g., in cement, polymer, epoxy system)
according to the present invention using any suitable magnetic
field generator, induction coil apparatus, and/or power system
and/or control system and/or connectors, connections, leads, metal
tubulars themselves, wires and/or power cables, insulated or not,
in the earth adjacent the material, in the material, on the
exterior of a tubular and/or on the interior of a tubular.
Optionally, electric current is sent via a transmitted wave or
signal (with a wired system and/or wirelessly) to a suitable
receptor for conversion to electrical current for application to
the material. Optionally, a generator in the earth, in the
wellbore, or in a tubular in the wellbore generates the needed
electricity to produce heat.
[0010] Heat generated in material (e.g., in cement, in polymers,
swellable material, shape memory material, in an epoxy system)
according to the present invention and/or in systems according to
the present invention can be used to heat the material and, in
certain aspects, to heat things and materials either in contact
with the material or in proximity to the material; e.g., but not
limited to, tubulars (e.g., casing, collars, pipe, or tubing),
fluid and/or materials in such tubular, fluid and/or materials
outside a tubular, e.g. fluid or materials in an annulus between a
tubular exterior and a wellbore or tubular exterior, and earth or
formations adjacent the material; e.g., but not limited to,
adjacent cement in a wellbore.
[0011] Accordingly, the present invention includes features and
advantages which are believed to enable it to advance wellbore
technology and wellbore production technology. Characteristics and
advantages of the present invention described above and additional
features and benefits will be readily apparent to those skilled in
the art upon consideration of the following description of
preferred embodiments and referring to the accompanying
drawings.
[0012] Certain embodiments of this invention are not limited to any
particular individual feature disclosed here, but include
combinations of them distinguished from the prior art in their
structures, functions, and/or results achieved. Features of the
invention have been broadly described so that the detailed
descriptions of embodiments preferred at the time of filing for
this patent that follow may be better understood, and in order that
the contributions of this invention to the arts may be better
appreciated. There are, of course, additional aspects of the
invention described below and which may be included in the subject
matter of the claims to this invention. Those skilled in the art
who have the benefit of this invention, its teachings, and
suggestions will appreciate that the conceptions of this disclosure
may be used as a creative basis for designing other structures,
methods and systems for carrying out and practicing the present
invention. The claims of this invention are to be read to include
any legally equivalent devices or methods which do not depart from
the spirit and scope of the present invention.
[0013] What follows are some of, but not all, the objects of this
invention. In addition to the specific objects stated below for at
least certain embodiments of the invention, other objects and
purposes will be readily apparent to one of skill in this art who
has the benefit of this invention's teachings and disclosures. It
is, therefore, an object of at least certain embodiments of the
present invention to provide the embodiments and aspects listed
above and:
[0014] New, useful, unique, efficient, nonobvious systems and
methods for completing a wellbore for fluid production
therefrom;
[0015] New, useful, unique, efficient, nonobvious wellbore casing
cements which include inductively heatable material, electrically
conductive material, and/or electrically conductive nanomaterial
therein to heat the cement and, in some aspects, material and/or
earth in contact with and/or adjacent the heated cement;
[0016] New, useful, unique, efficient, nonobvious wellbore
materials with nanomaterial therein; and cements and systems and
methods for cementing casing in a wellbore; and
[0017] New, useful, unique, efficient, nonobvious systems and
methods for heating all, a part of, or parts of cement that cements
casing in a wellbore.
[0018] New, useful, unique, efficient, nonobvious wellbore
materials which include new and nonobvious swellable materials; new
and nonobvious shape memory materials; and new and nonobvious
inductively heatable material, electrically conductive material,
microwave heatable material, and/or electrically conductive
nanomaterial therein to heat the wellbore material (e.g., cement,
polymers, swellable material, shape memory material, composites,
epoxy systems, e.g., but not limited to, two-part epoxy systems)
and, in some aspects, material and/or earth in contact with and/or
adjacent the heated material; and
[0019] New, useful, unique, efficient, nonobvious systems and
methods for heating all, a part of, or parts of material in a
wellbore e.g, but not limited to, cement that cements casing in a
wellbore.
[0020] The present invention recognizes and addresses the problems
and needs in this area and provides a solution to those problems
and a satisfactory meeting of those needs in its various possible
embodiments and equivalents thereof. To one of skill in this art
who has the benefits of this invention's realizations, teachings,
disclosures, and suggestions, various purposes and advantages will
be appreciated from the following description of certain preferred
embodiments, given for the purpose of disclosure, when taken in
conjunction with the accompanying drawings. The detail in these
descriptions is not intended to thwart this patent's object to
claim this invention no matter how others may later attempt to
disguise it by variations in form, changes, or additions of further
improvements.
[0021] The Abstract that is part hereof is to enable the U.S.
Patent and Trademark Office and the public generally, and
scientists, engineers, researchers, and practitioners in the art
who are not familiar with patent terms or legal terms of
phraseology to determine quickly, from a cursory inspection or
review. the nature and general area of the disclosure of this
invention. The Abstract is neither intended to define the
invention, which is done by the claims, nor is it intended to be
limiting of the scope of the invention or of the claims in any
way.
[0022] It will be understood that the various embodiments of the
present invention may include one, some, or all of the disclosed,
described, and/or enumerated improvements and/or technical
advantages and/or elements in claims to this invention.
[0023] Certain aspects, certain embodiments, and certain preferable
features of the invention are set out herein. Any combination of
aspects or features shown in any aspect or embodiment can be used
except where such aspects or features are mutually exclusive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] A more particular description of embodiments of the
invention briefly summarized above may be had by references to the
embodiments which are shown in the drawings which form a part of
this specification. These drawings illustrate embodiments preferred
at the time of filing for this patent and are not to be used to
improperly limit the scope of the invention which may have other
equally effective or legally equivalent embodiments.
[0025] FIG. 1 is a schematic view--not to scale--of a prior art
cased cemented wellbore.
[0026] FIG. 2 is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0027] FIG. 3 is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0028] FIG. 4 is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0029] FIG. 5A is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0030] FIG. 5B is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0031] FIG. 5C is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0032] FIG. 5D is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0033] FIG. 6 is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0034] FIG. 7 is a schematic view--not to scale--of a cased
cemented wellbore according to the present invention.
[0035] FIG. 8A is a side cross-sectional view of a well bore and a
casing to be cemented therein having a cementing plug assembly
installed in its initial position in the casing.
[0036] FIG. 8B is a view similar to FIG. 8A, but showing the well
bore and casing after a displacement plug of the cementing plug
assembly has been released and landed on a float collar in the
casing.
[0037] FIG. 8C is a view similar to FIG. 8B, but showing the well
bore and casing after a bottom plug of the cementing plug assembly
has been released and landed on the displacement plug.
[0038] FIG. 8D is a view similar to FIG. 8C, but showing the well
bore and casing after a top plug of the cementing plug assembly has
been released and landed on the bottom plug.
[0039] FIG. 9A is a fragmentary cross-sectional illustration of an
embodiment of a step in a method according to the present
invention.
[0040] FIG. 9B is a fragmentary cross-sectional illustration of an
embodiment of a step in a method according to the present invention
after the previous step.
[0041] FIG. 9C is a fragmentary cross-sectional illustration of an
embodiment of a step in a method according to the present
invention.
[0042] FIG. 9D is a fragmentary cross-sectional illustration of an
embodiment of a step in a method according to the present invention
after the previous step.
[0043] FIG. 9E is a fragmentary cross-sectional illustration of an
embodiment of a step in a method according to the present invention
after the previous step.
[0044] FIG. 10A is a side schematic view of a cementing system
connected to a well head with suitable piping for making a cemented
wellbore according to the present invention and includes a cement
delivery system and well head.
[0045] FIG. 10B is a side schematic view of a cemented wellbore
according to the present invention showing a casing with cement in
an annular space with zones with different cement.
[0046] FIG. 10C is a side schematic view of a cemented wellbore
according to the present invention showing a casing with cement in
an annular space with zones with different cement.
[0047] FIG. 11 a side schematic view of a cemented wellbore
according to the present invention.
[0048] FIG. 12 a schematic view of a system and method according to
the present invention. Nanomaterial is not depicted to scale in any
drawing.
[0049] FIG. 13 is a schematic view of a system using swellable
material according to the present invention.
[0050] FIG. 14A is a crosssection view of material according to the
present invention.
[0051] FIG. 14B is a crosssection view of the material of FIG. 14A
post-expansion.
[0052] FIG. 15A is a crosssection view of material according to the
present invention.
[0053] FIG. 15B is a crosssection view of material according to the
present invention.
[0054] FIG. 15C is a crosssection view of material according to the
present invention.
[0055] FIG. 15D is a crosssection view of the material of FIG. 15A
post-expansion.
[0056] FIG. 16A is a perspective view of a tubular with swellable
material according to the present invention.
[0057] FIG. 16B is a cutaway view of the tubular of FIG. 16A.
[0058] Certain embodiments of the invention are shown in the
above-identified figures and described in detail below. Various
aspects and features of embodiments of the invention are described
below and some are set out in the dependent claims. Any combination
of aspects and/or features described below or shown in the
dependent claims can be used except where such aspects and/or
features are mutually exclusive. It should be understood that the
appended drawings and description herein are of certain embodiments
and are not intended to limit the invention or the appended claims.
On the contrary, the intention is to cover all modifications,
equivalents and alternatives falling within the spirit and scope of
the invention as defined by the appended claims. In showing and
describing these embodiments, like or identical reference numerals
are used to identify common or similar elements. The figures are
not necessarily to scale and certain features and certain views of
the figures may be shown exaggerated in scale or in schematic in
the interest of clarity and conciseness.
[0059] As used herein and throughout all the various portions (and
headings) of this patent, the terms "invention", "present
invention" and variations thereof mean one or more embodiments, and
are not intended to mean the claimed invention of any particular
appended claim(s) or all of the appended claims. Accordingly, the
subject or topic of each such reference is not automatically or
necessarily part of, or required by, any particular claim(s) merely
because of such reference. So long as they are not mutually
exclusive or contradictory any aspect or feature or combination of
aspects or features of any embodiment disclosed herein may be used
in any other embodiment disclosed herein. The drawing figures
present the embodiments preferred at the time of filing for this
patent.
DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS
[0060] It is within the scope of the present invention, in any
embodiment described below, to substitute for the electrically
conductive nanomaterial, electrically conductive material that is
sufficiently resistively heatable to effect the desired heating
and/or microwave heatable material. It is within the scope of the
present invention, in any embodiment described below, to substitute
for the electrically conductive nanomaterial, inductively heatable
material that is sufficiently inductively heatable to effect the
desired heating and/or microwave heatable material; and in such
embodiments, any power source below may be changed to a magnetic
field apparatus useful in inductive heating, e.g., but not limited
to, induction coil apparatuses and/or changed to a suitable
apparatus for applying microwaves to microwave heatable material.
It should also be understood that it is within the scope of the
present invention to use a combination of any of these
materials--electrically conductive material, inductively heatable
material, microwave heatable material, and electrically conductive
nanomaterial--in a single material in or for introduction into a
wellbore, e.g., but not limited to, cements, polymers, shape memory
material, swellable material, composites, and/or epoxy systems,
including, but not limited to, two-part epoxy systems and, in
certain particular aspects, in a single cement or in a single zone
of a wellbore.
[0061] FIG. 2 shows a cemented cased wellbore Q with electrically
conductive nanomaterial NM (e.g., but not limited to, carbon
nanotubes) throughout the cement. Electricity is imposed on the
nanomaterial in the cement via leads A and B. As is true for any
embodiment described below, the material NM may be replaced by, or
used with, one or a combination of (combinations including any two
or three of these materials or a combination of any one or two of
them with electrically conductive nanomaterial) resistively
heatable electrically conductive material; inductively heatable
material; microwave heatable material. "Microwave heatable
material" as used herein may include any of the nanomaterials
disclosed or referred to herein that is microwave heatable.
[0062] FIG. 3 shows a cemented cased wellbore R with electrically
conductive nanomaterial NM (e.g., but not limited to, carbon
nanotubes) in discrete portions X and Y of the cement. Electricity
is imposed on the cement portion X via leads C and D and/or the
cement portion Y by leads E and F (all leads going to a power
source either in the well or at the surface).
[0063] It is within the scope of the present invention to have any
number of spaced-apart portions of cement in a wellbore (e.g., one,
two, three, four or multiple portions throughout a wellbore or
multiple spaced-apart portions in an area of a wellbore adjacent a
particular formation) with electrically conductive nanomaterial
therein so that any part of the wellbore and of adjacent formation
can be selectively heated.
[0064] FIG. 4 shows a perforated zone Z in a cased cemented
wellbore S with electrically conductive nanomaterial NM in the
cement adjacent the perforated zone. This part of the cement in the
zone Z can be selectively heated via leads G and H with a power
source PS at the surface or with a power source PC in the well, or
with both. Any suitable AC or DC power source or sources may be
used (as is true for any embodiment according to the present
invention). It is believed that heating the formation FO around the
zone Z may, in some cases, facilitate production from the
formation. As is true for any embodiment of the present invention
(including, but not limited to, those described above and below)
instead of or in addition to the power source PS, depending on the
material to be heated, a magnetic field apparatus may be used
and/or an apparatus for applying microwaves to microwave heatable
material may be used and the subject matter of the various drawing
figures that shows a power source may be changed so that the power
source is deleted and a magnetic filed source and/or microwave
source is used.
[0065] FIG. 5A shows a cased cemented wellbore 1 with electrically
conductive nanomaterial NM (not to scale) in cement T with one lead
C at the bottom of the cement and extending up through the earth
and one lead D extending through the earth to an upper part of the
cement.
[0066] FIG. 5B shows a cased cemented wellbore 2 with electrically
conductive nanomaterial NM (not to scale) in cement T with one lead
E at the top of the cement and connected to the interior of the
casing and one lead F extending through the earth to the bottom of
the cement T. The lead E may be insulated and may pass through the
casing to contact the cement.
[0067] FIG. 5C shows a cased cemented wellbore 3 with electrically
conductive nanomaterial NM (not to scale) in cement T with one lead
G at the top of the cement and connected to the interior of the
casing and one lead H extending through the casing's interior to
the bottom of the cement T. The leads may contact the casing itself
or the leads may be insulated and may pass through the casing to
contact the cement.
[0068] FIG. 5D shows a cased cemented wellbore 4 with electrically
conductive nanomaterial NM (not to scale) in cement T with one lead
K at the top of the cement and passing through or connected to the
interior of the casing and one lead L extending through the earth
to the bottom of the cement T. The lead K may contact the casing
itself or the lead K may be insulated and may pass through the
casing to contact the cement.
[0069] Power may be supplied to the leads of the systems of FIGS.
5A-5D via a surface power generator PG (see e.g. FIG. 5A) or via a
power generator PE in the earth (see FIG. 5B), or via a power
generator PR within the casing (see FIG. 5C). Optionally, a power
source PU either at the surface, as shown, or in the casing or in
the earth (not shown) receives a wave or signal from an appropriate
device or system and converts the wave or signal to electric power
for application to the leads K and L. Power may be supplied to any
system or cement according to the present invention with any of the
power sources of FIGS. 5A-5D. When inductively heatable material is
used instead or or in addition to cement, a magnetic field is
applied the inductively heatable material via a surface apparatus
or via an apparatus in the earth, or via an apparatus within the
casing. Optionally, such an apparatus either at the surface or in
the casing or in the earth receives a wave or signal from an
appropriate device or system and converts the wave or signal to
power for application of the magnetic field. When microwave
heatable material is used instead of or in addition to cement
and/or inductively heatable material, microwaves are applied the
inductively heatable material via a surface apparatus or via an
apparatus in the earth, or via an apparatus within the casing.
Optionally, such an apparatus either at the surface or in the
casing or in the earth receives a wave or signal from an
appropriate device or system and converts the wave or signal to
power for application of the microwaves.
[0070] As is true of any wellbore, any system and any method
according to the present invention, a cased wellbore according to
the present invention, as exemplified by the wellbores in the
drawing figures hereof, can be made with any known drilling and
completion method that involves the cementing of casing in a
wellbore, including, but not limited to, typical drilling and
cementing operations and also, without limitation, casing drilling
methods, rotary drilling methods, top drive drilling methods and
coiled tubing drilling methods.
[0071] FIG. 6 shows a wellbore 60 according to the present
invention in the earth 67. Casing 61 is cemented in the wellbore 60
with cement 62. Portions 63, 64 and 65 of the cement 62 have
electrically conductive nanomaterial NM therein. The portions 63,
64, 65 are spaced-apart any desirable distance and they may be
located adjacent different earth formations. There may be the three
portions shown or, according to the present invention, there may be
two or any number of such portions at any part of or throughout the
wellbore.
[0072] A power supply 66 supplies electrical current to the
nanomaterial NM in the portions 63, 64, 65. All portions can be
heated simultaneously; one or two portions may be selectively
heated; or the portions may be sequentially heated from top to
bottom or from bottom to top.
[0073] FIG. 7 shows a wellbore 70 according to the present
invention in the earth 77. Casing 71 is cemented in the wellbore 70
with cement 72. Portions 73, 74 and 75 of the cement 72 have
electrically conductive nanomaterial NM therein. The portions 73,
74, 75 are spaced-apart any desirable distance and they may be
located adjacent different earth formations. There may be the three
portions shown or, according to the present invention, there may be
two or any number of such portions at any part of or throughout the
wellbore.
[0074] A power supply 76 (within the earth as shown or at the
surface or within the wellbore--as is true for the power supply 66)
supplies electrical current to the nanomaterial NM in the portions
73, 74, 75. All portions can be heated simultaneously; one or two
portions may be selectively heated; or the portions may be
sequentially heated from top to bottom or from bottom to top.
[0075] As shown in FIG. 7, the density (or concentration) of
nanomaterial NM in the portion 73 is less than the density of
nanomaterial NM in the portion 74; and the density of nanomaterial
NM in the portion 75 is denser than that of the nanomaterial NM in
the portion 74. In one aspect, it is possible to heat the portion
75 faster than the portions 74 and 73 due to the presence of more
nanomaterial per unit volume in the portion 75; and/or it is
possible to heat the portion 75 to a higher temperature than the
other two portions for the same reason. It is to be understood that
heating of the portions 63-65 and/or 73-75, can, according to the
present invention, be used to heat the earth in contact with or
adjacent these portions and/or to heat the casing adjacent these
portions and/or the contents of the casing adjacent these portions.
In Any embodiment herein, the nanomaterial may be present at any
level, at any desired weight percent for effecting, e.g., an
increase in strength, an increase in thermal conductivity, and/or
an increase in electrical conductivity; e.g., the nanomaterial may
be present between 0.1 and 10 weight percent.
[0076] The power supplies 66 and 76 and the leads, cables,
connections, etc. for them may be any power source or supply and
leads, etc. disclosed herein. Any control system may be used with
the power supplies 66 and 76, e.g. like the control system CS FIG.
10A or any of the options disclosed for the system CS.
[0077] The present invention provides improvements to various
existing wellbore cementing methods. In one aspect, the present
invention provides methods which in some ways are similar to those
disclosed in U.S. Pat. No. 5,829,523, incorporated fully herein for
all purposes. In certain embodiments of the present invention, in
cementing casing or liners (both referred to hereinafter as
"casing") in well bores (sometimes referred to as "primary
cementing"), a cement slurry containing electrically conductive
nanomaterial is pumped downwardly through the casing to be cemented
and then upwardly into the annulus between the casing and the walls
of the well bore. Upon setting, the cement bonds the casing to the
walls of the well bore and restricts fluid movement between
formations or zones penetrated by the well bore. Prior to this, the
casing is suspended in a well bore and both the casing and the well
bore are filled with drilling fluid. In order to reduce
contamination of the cement slurry at the interface between it and
the drilling fluid, a cementing plug for sealingly engaging the
inner surfaces of the casing is pumped ahead of the cement slurry
whereby the cement slurry is separated from the drilling fluid as
the cement slurry and drilling fluid ahead of it are displaced
through the casing. The cementing plug wipes the drilling fluid
from the walls of the casing and maintains a separation between the
cement slurry and drilling fluid until the plug lands on a float
collar attached near the bottom end of the casing.
[0078] The cementing plug which precedes the cement slurry and
separates it from drilling fluid is referred to herein as the
"bottom plug." When the predetermined required quantity of the
cement slurry has been pumped into the casing, a second cementing
plug, referred to herein as the "top plug", is released into the
casing to separate the cement slurry from additional drilling fluid
or other displacement fluid used to displace the cement slurry.
When the bottom plug lands on the float collar attached to the
casing, a valve mechanism opens which allows the cement slurry to
proceed through the plug and the float collar upwardly into the
annular space between the casing and the well bore. The design of
the top plug is such that when it lands on the bottom plug it shuts
off fluid flow through the cementing plugs which prevents the
displacement fluid from entering the annulus. After the top plug
lands, the pumping of the displacement fluid into the casing is
continued whereby the casing is pressured up and the casing and
associated equipment including the pump are pressure tested for
leaks or other defects.
[0079] The present invention provides, in certain aspects, methods
which include releasing a first displacement plug (e.g., but not
limited to, as in U.S. Pat. No. 5,829,523) into the casing which is
selectively openable after landing on a float collar. A first
displacement fluid is then pumped behind the first displacement
plug while measuring the quantity of the first displacement fluid
being pumped until the first displacement plug is displaced through
the casing and lands on a float shoe contained in the casing. The
first displacement plug is caused to open, and a cement slurry
which has nanomaterials therein (any cement according to the
present invention) is pumped into the casing in a predetermined
quantity required to fill the annulus between the exterior of the
casing and the walls of the well bore with the cement slurry. After
the predetermined quantity of cement slurry is pumped into the
casing, a top cementing plug is released into the casing. A second
displacement fluid is then pumped behind the top cementing plug to
displace the cement slurry through the casing and through the open
displacement plug into the annulus. The second displacement fluid
is pumped in a quantity substantially equal to the quantity of the
first displacement fluid as measured during the displacement of the
first displacement plug thereby ensuring that the cement slurry is
not under or over displaced in the annulus.
[0080] As shown in FIGS. 8A-8D, a well cementing plug assembly (any
known suitable assembly, e.g., but not limited to, as shown in U.S.
Pat. No. 5,829,523) is illustrated and generally designated by the
numeral 810. The plug assembly 810 is shown positioned within a
string of casing 812 which is suspended in a well bore 814
preparatory to being cemented therein. The plug assembly 810 is in
its initial position in the casing 812 whereby it is releasably
connected to the lower end of a string of drill pipe or a
conventional circulation tool 816. The casing 812 includes a
conventional float collar 824 connected therein near the bottom
thereof. A conventional float shoe 832 is connected to the bottom
end of the casing 812 separated from the float collar 824 by a
distance 830.
[0081] In one version of a cementing plug assembly 810, the
assembly has a selectively operable displacement plug 818 which is
releasably connected to a selectively operable bottom cementing
plug 820. The bottom cementing plug 20 is in turn releasably
connected to a top cementing plug 822. The top cementing plug 822
is releasably connected to the drill pipe or circulation tool
816.
[0082] The displacement plug 818 and bottom cementing plug 820 are
both separately closed and released by dropping different sizes of
releasing plugs, e.g., balls, therein and then increasing the
differential fluid pressures exerted on the plugs to predetermined
differential fluid pressures which cause their release as will be
described further herein below. When the displacement plug 818
lands on the float shoe 824 and when the bottom plug 820 lands on
the displacement plug 818, the plugs are separately caused to open.
That is, the displacement and bottom plugs are opened by again
increasing the differential fluid pressures exerted on them to
predetermined differential fluid pressures. The top cementing plug
822 is also closed and released by dropping a releasing plug, e.g.,
a drill string or tubing plug, therein and exerting a predetermined
differential fluid pressure thereon.
[0083] Both the casing 812 to be cemented and the well bore 814 are
usually filled with drilling fluid prior to commencing primary
cementing operations. After suspending the casing string 812 in the
well bore 814 and positioning the cementing plug assembly 810
within the casing 812 as shown in FIG. 8A, a releasing plug RP of a
predetermined relatively small size is dropped into and caused to
be moved in a known manner through the drill string or circulation
tool 816, through the plug assembly 810 and into the displacement
plug 818. The releasing plug closes the displacement plug 818 and a
first predetermined differential fluid pressure is then exerted on
the displacement plug 818 which causes its release from the
assembly 810. A first displacement fluid, such as drilling fluid,
is pumped behind the closed displacement plug so that the
displacement plug is moved through the casing and lands on the
float collar 824 as shown in FIG. 8B. The displacement plug 818
slidably and sealingly engages the walls of the casing 812 as it is
moved through the casing and it separates and prevents mixing of
the fluids on its opposite sides, i.e., drilling fluid 826 below
the displacement plug 818 which was in the casing prior to the
release of the displacement plug 818 and the first displacement
fluid 828 above the displacement plug 818. Optionally, as the
displacement plug 818 is moved through the casing 812, the quantity
of the first displacement fluid being pumped is measured by a
volume meter, a pump stroke counter or other volume measurement
device whereby when the displacement plug 818 lands on the float
collar 824, the total quantity of displacement fluid required to
move the displacement plug 818 from the assembly 810 to the float
shoe is known.
[0084] When the displacement plug 818 lands on the float collar
824, the movement of the displacement plug 818 and the flow of the
first displacement fluid is stopped whereby the pressure within the
casing 812 above the displacement plug 818 is increased. Such
pressure increase is seen in the displacement fluid pressure
indicated at the surface whereby the drilling rig operator knows
the displacement plug 818 has landed and can then observe or
otherwise determine the total quantity of the first displacement
fluid pumped. Thereafter, the first displacement fluid pressure is
increased by continued pumping until a second predetermined
differential fluid pressure is reached which opens the displacement
plug 818 in a manner which will be described herein below.
[0085] A length 830 of the casing 812 extends between the float
collar 824 and the float shoe 832 attached to the bottom end of the
casing 812. The length of casing 830 between the float collar 824
and the float shoe 832 is known in the art as the shoe track and
will be referred to hereinafter as the shoe track 830. During the
travel of the displacement plug 818 from the assembly 810 to the
float collar 824, the drilling fluid 826 below the displacement
plug 818 is displaced through the float collar 824, through the
shoe track 830 and through the float shoe 832 into the annulus 834
between the casing 812 and the walls of the well bore 814. Once the
displacement plug 818 has landed on the float collar 824, the total
quantity of the first displacement fluid pumped has been measured
and the displacement plug 818 has been opened, a second releasing
plug of a predetermined medium size as compared to the first
releasing plug is dropped into the bottom cementing plug 820
whereby the bottom cementing plug 820 is closed. A cement slurry
836 is then pumped through the drill string or circulation tool 816
whereby a third predetermined differential fluid pressure is
exerted on the bottom cementing plug 820 and it is released. The
cement slurry contains electrically conductive nanomaterial NMT
(not shown to scale; any such nanomaterial disclosed herein
according to the present invention). The cement slurry 836 is
pumped into the casing 812 behind the bottom plug 820 in a
predetermined quantity required to fill the annulus 834. As the
bottom plug 820 moves through the casing 812, the first
displacement fluid 828 is displaced through the displacement plug
818, through the float collar 824, through the shoe track 830,
through the float shoe 32 and into the annulus 834. The cement
slurry 836 is pumped, and if necessary displaced, into the casing
812 until the bottom plug 820 lands on the displacement plug 818 as
shown in FIG. 8C. The pumping or displacement of the cement slurry
836 is then continued to increase the fluid pressure exerted on the
bottom cementing plug 820 until a fourth predetermined differential
fluid pressure is reached which causes the bottom cementing plug
820 to open and the cement slurry 836 to flow through it, through
the displacement plug 818, through the float collar 824, through
the shoe track 830, through the float shoe 832 and into the annulus
834.
[0086] When the predetermined quantity of cement slurry 836 has
been pumped into the casing 812, a third releasing plug of a
predetermined large size as compared to the second releasing plug
is dropped into the top cementing plug 822 which closes the top
cementing plug 822. A second displacement fluid 838, which
preferably is the same as or at least has very similar properties
to the first displacement fluid 828 used, is pumped behind the top
cementing plug 822. The fluid pressure exerted on the top cementing
plug 822 by the second displacement fluid 838 is increased to a
fifth predetermined differential fluid pressure which causes the
top cementing plug 822 to be released. Thereafter, a quantity of
the second displacement fluid 838 substantially equal to the
previously measured quantity of the first displacement fluid 828 is
pumped. The pumped quantity of the second displacement fluid 838 is
preferably measured using the same flow meter or other measuring
device which was used to measure the quantity of the first
displacement fluid thereby assuring that the two quantities are the
same or substantially the same.
[0087] The cement slurry 836 is displaced through the casing 812,
through the bottom cementing plug 820, through the displacement
plug 818, through the float collar 824, through the shoe track 830
and through the float shoe 832 into the annulus 834 as shown in
FIG. 8D. When the top cementing plug 822 lands on the bottom
cementing plug 820, the top cementing plug terminates the flow of
the second displacement fluid 838 and prevents it from flowing into
the shoe track 830 or the annulus 834. The pumping of the measured
quantity of the second displacement fluid 838 allows the rig
operator to know that the top plug 822 has landed whereupon the
operator can proceed to pressure test the casing 812 and associated
equipment. The cement slurry 836 in the annulus 834 and the shoe
track 830 is then allowed to set whereby the casing 812 and shoe
track 30 are cemented in the well bore. Thereafter, the
displacement plug 818, the cementing plugs 820 and 822, the
internals of and set cement in float collar 824, the set cement in
the shoe track 830 and the internals of and set cement in the float
shoe 832 are all drilled out of the casing 812 whereupon the well
is completed or additional well bore is drilled below the casing
812.
[0088] In accordance with certain aspects of the present invention,
the quantity of the second displacement fluid 838 utilized for
displacing the top cementing plug 822 and the cement slurry 836
through the casing 812 and into the annulus 834 is a quantity
substantially equal to the quantity of the first displacement fluid
828 measured when the displacement plug 818 was displaced through
the casing 812 with the first displacement fluid 828. The first and
second displacement fluids are preferably the same or very similar
fluids, e.g., drilling fluid, and are preferably measured by the
same flow meter or other measuring device to ensure as much as
possible that the quantities of the first and second displacement
fluids are equal or at least substantially equal. Thus, the
quantity of the second displacement fluid 838 required to displace
the cement slurry 836 into the annulus 834 and land the top
cementing plug 822 is positively determined.
[0089] It is within the scope of the present invention that some
operators may prefer to omit the use of the bottom cementing plug
820, and instead utilize a two plug assembly consisting of the
displacement plug 818 and the top cementing plug 820. Also it is
within the scope of the present invention that the displacement
plug and one or two cementing plugs used be released from the
surface separately in any suitable manner and do not necessarily
need to be releasably connected in an assembly as described
above.
[0090] A wellbore made as in FIGS. 8A-8D may have any device or
system described herein for imposing a current on the nanomaterial
in the cement.
[0091] Referring to FIG. 9A, a method 910 according to the present
invention is illustrated for cementing a wellbore 912 which employs
a system that includes a shoe 914 defining a passage 914a that is
coupled to an end of a tubular member 916 defining a passage 916a.
The tubular member 916 includes one or more tubular members
threadably coupled end to end. The other end of the tubular member
916 is coupled to an end of a float collar 918 including a float
918a. The other end of the float collar 918 is coupled to an end of
a tubular member 920 defining a passage 920a. Centralizers 922a,
922b, and 922c are coupled to the exteriors of the tubular members,
916 and 918. More generally, the system may include any number of
centralizers. The other end of the tubular member 920 is coupled to
a fluid injection assembly 924 defining a passage 924a and radial
passages 924b, 924c, and 924d, and including retaining pins 924e
and 924f. The fluid injection head 924 is commonly referred to as a
cementing head. A bottom cementing plug 926 and a top cementing
plug 928 are retained within the passage 924a of the fluid
injection assembly 924 by the retaining pins 924e and 924f. The
bottom cementing plug 926 typically includes a longitudinal passage
that is sealed off by a frangible diaphragm.
[0092] During operation, as illustrated in FIG. 9A, drilling mud
930 is circulated through the wellbore 912 by injecting the
drilling mud into the fluid injection assembly 924 through the
radial passage 924b. The drilling mud 930 then passes through the
passages 924a, 920a, 918a, and 914a into the annulus between the
tubular member 920, the float collar 918, the tubular member 916,
and the shoe 914. As illustrated in FIG. 9B, the bottom cementing
plug 926 is then released and a spacer fluid 932 followed by a
cement slurry 934 are injected into the injection assembly 924
through the radial passage 924c behind and above the bottom
cementing plug. The cementing slurry 934 contains sufficient
electrically nanomaterial NML (not shown to scale) that upon the
imposition of an electric current thereon, the nanomaterial NML is
resistively heated which in turn heats cement resulting from
setting and hardening of the cement slurry 934. As illustrated in
FIG. 9C, the top cementing plug 928 is then released and a
displacing fluid 936 is injected into the injection assembly 924
through the radial passage 924d behind and above the top cementing
plug. As illustrated in FIG. 9D, the continued injection of the
displacing fluid 936 displaces the bottom cementing plug 926 into
contact with the float collar 918 and breaks the frangible membrane
of the bottom cementing plug thereby causing the cement slurry 934
to flow into the annulus between the wellbore 912 and the shoe 914,
the tubular member 916, the float collar 918, and the tubular
member 920. As illustrated in FIG. 9E, the continued injection of
the displacing fluid 936 then displaces the top cementing plug 928
downwardly until the top cementing plug impacts the bottom
cementing plug 926. The float element 918a of the float collar 918
prevents back flow of the cement slurry 934 into the tubular member
920. The cement slurry 934 may then be allowed to cure.
[0093] A wellbore made as in FIGS. 9A-9E may have any device or
system described herein for imposing a current on the nanomaterial
in the cement.
[0094] As shown in FIG. 10A, a wellbore 1000 according to the
present invention has multiple zones (Sectors 1, 2,3) with
different cements 1027, 1026, 1025, respectively, according to the
present invention which can be any cement disclosed herein
according to the present invention. Electrically conductive
nanomaterial is represented schematically by the material NME, NMF,
NMG (may be different materials, similar materials, at the same or
at different concentrations; not to scale). The cements can be
prepared off site, or, as shown, can be mixed in the field and
delivered through pumps 1011 into a manifold 1012. The manifold is
connected to a well head at 1013. As appropriate, a suitable valve
(or valves) 1014 is interposed between them. The cement is
delivered under suitable pressures at selected flow rates. The
nature of the cement is variable and the cements 1025-1027 may each
be any cement disclosed herein according to the present invention;
and they may each be a different cement, any two of them may be the
same, or they may all three be the same. It is to be understood
that a wellbore according to the present invention may have any
multiple number of cement zones, although only three are depicted
in FIG. 10A. Optionally, a supply apparatus 1010 may supply
different cements and/or other fluids to be used in the cementing
process. In certain aspects, two or three different cements and/or
fluids may be pumped into the well to complete the cementing job.
The manifold 1012 is used to deliver these cements and/or fluids
into the well. The pump 1011 is connected with suitable supplies of
various fluids for delivery into the well.
[0095] At the wellhead, an optional flow meter 1015 measures the
rate of flow which can be expressed in barrels per minute. This is
the rate of flow of the cement and/or fluid delivered into the
well. The density of the fluid can also, optionally, be measured at
the wellhead by a transducer 1016. Density may be indicated in
pounds per gallon. As appropriate, a fluid analysis device 1017 may
be incorporated to make other measurements regarding the cement
and/or fluid. Transducers 1015, 1016 and device 1017 form output
data which is input to an analysis and control system CS which
controls the flow of the cement and/or fluid (the control system CS
may be any suitable known control system, including, but not
limited to, those disclosed in prior patents referred to herein).
Any wellbore and method disclosed herein according to the present
invention may have one or more of the control systems CS. Pressure
at the wellhead may be measured by a device 1018 and may be
expressed in pounds per square inch. The pressure device 1018 may
be calibrated up to several thousand psi. Pressures in this range
are not uncommon.
[0096] The wellhead 1013 is connected to a completion string in a
wellbore 1020. The wellbore 1020 may, according to the present
invention, be cased or open hole, and is represented in a very
general form in FIG. 10A. While there may be multiple completion
strings, FIG. 10A shows a representative single completion string
in the well. This is the string of pipe (or casing) to be cemented
in place in the well; this string of pipe can enclose a separate
tubing string or strings to conduct produced fluids, e.g. oil
and/or gas, to the surface. This string can be uniform from top to
bottom, but it can also be made in different sections. To this end,
an upper section is identified by the numeral 1021. This section is
casing or tubing of a specific diameter and flow characteristic and
has a certain length and extends to a selected depth in the bore
hole. The number 1022 identifies a second section which is serially
connected to a third section 1023. The sections 1021, 1022, and
1023 jointly comprise the completion string. They may be identical
and to that degree only a single section need be mentioned. On the
other hand, when they are different, they may be different lengths
and may be formed of different diameters of casing, tubing, and/or
pipe. As an example, the string can taper wherein the top section
is relatively large in diameter and the bottom section 1023 is much
smaller in diameter. The string terminates at a bottom located
opening 1024 which can be fitted with various and sundry known
landing nipples supported by packers, bridge plugs and the like;
they have been omitted for sake of clarity in the description of
the string and the associated equipment.
[0097] In general, pipe extends to the bottom or nearly so where
cement is delivered from the opening 1024. Cement flows into the
annular space and is delivered into the space to complete the
cementing job. This space has been represented in very general form
in FIG. 10A and will be understood to be that portion of the
wellbore where cement is to be delivered, and may, as desired, be
defined and isolated by packers or bridge plugs. The annular space
may also be temporarily or permanently filled with other fluids
either before or after the cement, all for the purpose of
completing the cement job and assuring that the cement bond between
the string and well bore is completed in the desired fashion. The
space is therefore set forth in very general form on the exterior
of the string. This fact remains true even should there by multiple
tubing strings to multiple zones along the well.
[0098] A flow meter 1015 and the other devices and transducers are
may be input into the system CS which may include, as needed, a
computer or computers and may be accessible on site and/or
remotely. Graphic displays may be provided.
[0099] In one aspect, the annular space is filled by cement,
cements, and/or fluids which are delivered serially. In one aspect,
a first cement is pumped out the opening 1024 at the bottom end of
the pipe and is a first cement 1044 which has a measured volume and
hence stands to a certain height in the annular space and it is
located above a subsequent amount of cement 1045. In one aspect,
three cements are pumped into the annular space. As shown in FIG.
10B the cement 1044 has been moved upwardly. The cement 1045 has
moved upwardly and it is supported by a third cement 1046 which has
introduced therebelow, flowing into the annular space The three
cements thus stand one on the other. There may be some interface
between them and/or they may flow with a relatively sharp
separation.
[0100] The cements may be isolated by adjacent slugs of other
materials which can aid and assist in positioning the cements at
the desired locations in the wellbore. This desired location may be
delineated by suitable packers and bridge plugs. As is true for any
embodiment herein, the cement (or any part thereof) may be heated
to facilitate its curing, solidifying, and/or setting
[0101] A wellbore made as in FIGS. 10A-10C may have any device or
system described herein for imposing a current on the nanomaterial
in the cement.
[0102] As depicted in FIG. 11, a tubular string 1112 (such as a
production, injection, drill, test or coiled tubing string) has
been installed in a wellbore 1114 cased with casing 1124 cemented
with cement 1126. The cement 1126 may be any cement according to
the present invention which has sufficient electrically conducting
nanomaterial NMA (not shown to scale) that, upon imposition of
electric current thereon, heats the cement, and/or the casing, the
interior of the casing, and/or the tubing, the interior of the
tubing and/or the earth formation adjacent the casing. An
electrical power generator 1116 is interconnected in the tubular
string 1112. The generator 1116 generates electrical power from
flow of fluid (represented by arrow 1118) through an internal flow
passage 1120 of the tubular string 1112. Optionally, the generator
1116 is disposed on an interior wall of the casing.
[0103] The fluid 1118 is shown as flowing upwardly through the
tubular string 1112 (as if the fluid is being produced), but it
should be clearly understood that a particular direction of flow is
not necessary in keeping with the principles of the invention. The
fluid 1118 could flow downwardly (as if being injected) or in any
other direction. Furthermore, the fluid 1118 could flow through
other passages (such as an annulus 1122 formed radially between the
tubular string 1112 and the wellbore 1114) to generate electricity,
if desired.
[0104] The generator 1116 is illustrated as being electrically
connected with lines 1131 and 1132 to the casing, but it is within
the scope of the present invention for any connection, lines,
cables, wireless apparatus, etc. disclosed herein to be used to
connect the generator 1116 to the casing, or through the casing to
the cement.
[0105] FIG. 12 illustrates a method 1200 according to the present
invention in which material 1202 ("PRIMARY MATERIAL IN OR FOR USE
IN A WELLBORE") which has within it material 1204 that is heatable
by the application of energy to it ("HEATABLE MATERIAL"). Energy is
applied to the heatable material by an energy source 1206 ("ENERGY
SOURCE"). The energy source 1206 is, as shown, spaced apart from
the material 1202 or (as shown with the dotted lines) the energy
source 1206 is in contact with the material 1202.
[0106] The material 1202 may be any material used in wellbore
operations, including, but not limited to, drilling fluid,
fracturing fluid, cement, polymers, composites, epoxy, epoxy
systems, and two-part epoxies. The heatable material 1204 may be
any known energy heatable material, e.g., but not limited to,
microwave heatable material, resistively heatable electrically
conductive material, and inductively heatable material heatable by
the application of a magnetic field. The heatable material may be
nanomaterial. The energy source may be any suitable source of
energy, including, but not limited to, apparatus for applying
microwaves, magnetic field apparatus such as apparatus with an
induction coil, and a power source of electrical current.
[0107] In certain aspects of the present invention wellbores
according to the present invention and methods according to the
present invention employ a power source for imposing an electric
current on electrically conductive nanomaterial. It is within the
scope of the present invention to use any suitable known power
source, battery, generator, capacitor, motor, or storage device for
supplying the electrical current, including, but not limited to,
those disclosed in U.S. Pat. Nos. 7,242,103; 7,699,102; 7,002,261;
7,133,325; 7,814,993; 7,717,167; 6,717,283; 6,672,409; 6,672,382;
6,554,074; 6,504,258; 6,470,970; 6,424,079; 6,179,052; 6,020,653;
5,995,020; 5,965,964; 5,626,200; 5,202,194; 4,416,000; 4,415,823;
4,215,426; 4,015,234; 3,968,387; and 3,448,305 and in each prior
reference cited in each of these patents--all said patents and said
references incorporated fully herein for all purposes; and the
control systems, communications systems, cabling, wireless
transmission apparatus etc. disclosed in these applications and
patents, when suitable, may be used with the wellbores and the
methods of the present invention.
[0108] It is within the scope of the present invention to use one,
two, three or greater multiples of any energy source, etc.
disclosed herein for a single wellbore, including, but not limited
to, those of FIGS. 5A-5D and FIG. 11. It is also to be understood
that the wellbore of FIG. 11 may have multiple zones with heatable
material, with one or more energy sources. Any energy source used
with embodiments according to the present invention that is movable
may be selectively moved to any desired point in a wellbore or in a
tubular (e.g., casing) to apply energy (electric current, magnetic
field, and/or microwaves) at any desired location.
[0109] The present invention, therefore, provides in at least
certain embodiments methods for cementing casing in a wellbore, the
methods in certain aspects including cementing all of or at least a
portion of a tubular, e.g., but not limited to, casing in a
wellbore with cement that contains electrically conductive
nanomaterial.
[0110] The present invention, therefore, provides in at least
certain embodiments methods for heating cement in a wellbore, the
methods in certain aspects including imposing an electrical current
on at least a portion of cement, said at least a portion of cement
containing electrically conductive nanomaterial that is heated upon
the imposition of the electrical current, the cement being any
cement used in a wellbore and, in one aspect, cement that cements
casing in a wellbore.
[0111] The present invention, therefore, provides in at least
certain embodiments methods for heating cement in a wellbore, the
methods in certain aspects including methods for heating casing
cemented in a wellbore with cement, the methods including imposing
an electrical current on all of or at least a portion of cement
that cements casing in a wellbore, said cement containing
electrically conductive nanomaterial that is heated upon the
imposition of the electrical current resulting in heating of the
nanomaterial, said heating of the nanomaterial causing heating of
the casing.
[0112] The present invention, therefore, provides in at least
certain embodiments methods for heating contents of a tubular in a
wellbore, the wellbore including cement therein, the methods in
certain aspects including heating the contents within a wellbore
(including, but not limited to contents within a tubular within a
wellbore, including but not limited to the contents of casing or of
tubing within a wellbore, including but not limited to the contents
of tubing within casing in a wellbore, the methods including:
imposing an electrical current on all of or at least a portion of
cement in a wellbore, the wellbore having contents or a tubular
within the wellbore having contents, said cement containing
electrically conductive nanomaterial heated upon the imposition of
the electrical current resulting in heating of the nanomaterial,
said heating of the nanomaterial causing heating of the contents in
the wellbore or causing heating of the tubular (e.g., tubing or
casing), said heating resulting in heating of the contents. In such
methods, in certain aspects, the contents is fluid, the fluid being
one of drilling fluid, oil, gas, and water.
[0113] The present invention, therefore, provides in at least
certain embodiments methods for heating earth formation adjacent
cement in a wellbore, the cement in the wellbore or the cement
around casing in the wellbore, the methods including: imposing an
electrical current on all of or on at least a portion of cement
that cements casing in a wellbore, said at least a portion of
cement containing electrically conductive nanomaterial that is
heated upon the imposition of the electrical current; said heating
of the electrically conductive nanomaterial causing heating of the
cement which in turn heats earth formation adjacent the cement. In
certain aspects, such a method in which the earth formation
contains fluid to be produced through the wellbore heating the
earth formation heats the fluid to be produced.
[0114] The present invention, therefore, provides in at least
certain embodiments methods for cementing a string of casing
disposed in a well bore which includes a float collar connected
near the bottom end thereof include the steps of: releasing a first
displacement plug into said casing which is selectively openable
after landing on said float collar; pumping a first displacement
fluid behind said first displacement plug until said first
displacement plug is displaced through said casing and lands on
said float collar; causing said first displacement plug to open;
pumping a cement slurry into said casing in a predetermined
quantity required to fill the annulus between the exterior of said
casing and the walls of said well bore with said cement slurry,
said cement slurry containing electrical conductive nanomaterial
which, upon the imposition of an electric current thereto, is
resistively heatable; and releasing a top cementing plug into said
casing and pumping a second displacement fluid behind said top
cementing plug to displace said cement slurry through said casing
and through said open displacement plug into said annulus. Such
methods may include allowing the cement to set forming solid
cement, and imposing an electric current on said electrical
conductive nanomaterial to resistively heat the electrically
conductive nanomaterial thereby heating the cement and/or imposing
an electric current on said electrical conductive nanomaterial to
resistively heat the electrically conductive nanomaterial thereby
facilitating the setting of the cement.
[0115] The present invention, therefore, provides in at least
certain embodiments methods for cementing a tubular string in a
wellbore, the methods including making a wellbore in the earth,
placing a tubular string in the wellbore, introducing cement into a
space between an exterior of the tubular string and an interior of
the wellbore, the cement containing electrically conductive
nanomaterial which is resistively heatable, and allowing the cement
to set. In such methods the cement can include amounts of different
cements each different cement located generally at a different
location in the space, and, optionally, each different cement
having a different concentration of electrically conductive
nanomaterial.
[0116] The present invention, therefore, provides in at least
certain embodiments methods for heating cement that is in a
wellbore and/or cement cementing casing in a wellbore, the methods
including: imposing an electrical current on all of or on at least
a portion of the cement, said cement containing sufficient
electrically conductive nanomaterial so that the cement is heated
upon the imposition of the electrical current, the electrical
current supplied by a power source, the electrical current being
one of alternating current and direct current, and, optionally, the
power source controlled on-site or remotely by a control system. In
such a method the power source may be any wired or wireless power
source or generator, fixed or movable, and may be controlled by a
control system that is one of on-site accessible and remotely
accessible.
[0117] The present invention, therefore, provides in at least
certain embodiments methods for heating cement that is in a
wellbore and/or that is cementing casing in a wellbore, the methods
including: imposing an electrical current on all of or on at least
a portion of cement, said cement containing sufficient electrically
conductive nanomaterial that the cement is heated upon the
imposition of the electrical current; the electrical current
supplied by a power source, the power source being located within
earth formation adjacent the casing, within the cement, within the
wellbore, at an earth surface, within the wellbore, or within the
casing.
[0118] The present invention, therefore, provides in at least
certain embodiments methods for heating cement that is in a
wellbore or that is cementing casing in a wellbore, the methods
including: imposing an electrical current on the cement, said
cement containing electrically conductive nanomaterial that is
heated upon the imposition of the electrical current, the cement
including spaced-apart amounts of different cements each different
cement located generally at a different location in the wellbore,
and heating the different cements at the same time or at different
times. Such methods may include one or some, in any possible
combination, of the following: the different cements are one on top
of the other and the heating is done from top to bottom of cements
so that a lowermost cement is heated last or the different cements
are one on top of the other and the heating is done from bottom to
top of the different cements so that a lowermost cement is heated
first; and/or each different cement has a different concentration
of electrically conductive nanomaterial.
[0119] The present invention, therefore, provides in at least
certain embodiments methods for cementing casing in a wellbore, the
method including cementing a casing in a wellbore with cement that
contains electrically conductive nanomaterial, the cement
comprising a plurality of spaced-apart cements each with a
different concentration of electrically conductive
nanomaterial.
[0120] The present invention, therefore, provides wellbores with
cement therein, the cement containing heatable electrically
conductive nanomaterial. In certain aspects, the wellbore is cased
with casing and the cement is heatable to heat the cement and/or to
heat the casing an/or to heat things or fluids in contact with or
near the heated cement and/or in contact with or near the
casing.
[0121] It is within the scope of the present invention to provide a
method for cementing a borehole that includes selecting a location
in the borehole for cementing and providing a cement slurry
including a cement (with or without nanomaterial therein, as any
nanomaterial disclosed herein, with the nanomaterial dispersed or
located therein in any way disclosed herein) and shape memory
members with nanomaterial thereon and/or therein (as any
nanomaterial disclosed herein, with the nanomaterial applied,
coated, dispersed or located therein or thereon in any way
disclosed herein) having a first shape, the shape memory members
configured to expand from the first shape to a second shape upon
application of heat to the shape memory members, placing the cement
slurry in a selected space and heating the shape memory members in
the selected space to attain the second shape. Such methods and
shape memory members are improvements of those disclosed in U.S.
Pat. No. 8,720,560 which is incorporated fully herein for all
purposes.
[0122] FIG. 13 shows a diagram of an exemplary borehole system 1300
using shape memory members made according to one embodiment of the
disclosure that may be utilized for cementing a borehole 1302. In
an embodiment, a cement slurry 1303 (referred to as "slurry" or
"cement") is directed downhole to cement the borehole. Optionally,
the cement slurry 1303 has nanomaterial therein (as any disclosed
herein). The borehole 1302 may include vertical, directional,
lateral and various degrees from vertical approaching lateral
boreholes formed in a formation 1304 for storage and/or retrieval
of fluids, such as sequestration or hydrocarbon production. As
depicted, a tubular 1306 is disposed in the borehole 1302, wherein
the tubular 1306 extends from surface 1310 to an end portion 1307
of the borehole. A derrick 1308 is located at the surface 130 to
support borehole equipment, including the tubular 1306.
[0123] In the depicted embodiment, a slurry system 1312 is located
proximate the surface. The slurry system 1312 is configured to
direct the cement slurry 1303 downhole, as shown by arrows 1314 and
1316. The cement slurry 1303 is directed downhole by an additive
source 1318, a slurry source 1320 and a pump 1322.
[0124] As depicted, the additive source 1318 provides an additive,
such as shape memory members, to be mixed with a cement slurry in
the slurry source 1320, prior to being directed downhole by the
pump 1322. The shape memory members may include known shape memory
members without nanomaterial according to the present invention in
combination with shape memory members according to the present
invention.
[0125] In another embodiment, the shape memory members are added to
and mixed with the cement slurry prior to being placed in the
slurry source 1320. Exemplary shape memory members are composed of
a polymer material and have a density that is less than that of the
cement slurry (with nanomaterial present at a selected loading
level so that a desired density is achieved). Thus, the addition of
shape memory members, in certain aspects, can reduce the density of
the slurry.
[0126] An exemplary cement slurry includes dry cement combined with
a water solution to create a wet cement or slurry (with or without
nanomaterial therein). The water solution can be fresh water, drill
water, sea water, brackish water, produced, flowback, mono-valent
or di-valent brines or another water solution. This may be
accomplished by use of selected mixers, including hydraulic jet
mixers, re-circulating mixers or batch mixers (including, when
present, use for mixing nanomaterial).
[0127] In an embodiment, shape memory members comprise a material
with shape memory or shape-conforming materials (also referred to
as "shape-memory materials"), members, apparatus and/or devices
made using such materials and methods of their use. In one aspect,
cement slurry additives are made from a suitable material,
including, but not limited to, syntactic and conventional memory
foams, a shape memory polymer (SMP), and/or a combination thereof.
As used herein, the term "memory" refers to the capability of a
material to withstand certain stresses, such as external mechanical
compression, vacuum and the like, but to then return, under
appropriate conditions, such as exposure to a selected form of
energy, often heat, to the material's original size and shape. Any
materials disclosed in U.S. Pat. No. 8,720,560 may be used. In
certain aspects, the shape memory material may be described as
having a "shape memory" property.
[0128] Still referring to FIG. 13, the initial (as-formed) shape of
the shape memory member comprised of the shape memory material may
vary, though a substantially spherical, cylindrical or squared
shape is well-suited to be mixed and distributed within a cement
slurry. In certain aspects, once the member of shape memory
material is compressed and cooled, it is added to the cement
slurry, which may then be directed downhole.
[0129] In an embodiment, the cement slurry is pumped along the
tubular 1306 wherein it is released near the end portion 1307 of
the borehole and directed into an annulus 1324, as shown by arrows
1316. The cement slurry may also be utilized to combat a "loss of
circulation" zone which may occur in the wellbore or casing while
drilling, static, production or completion operations are in
process. The exemplary cement slurry then hardens in the desired
location, such as annulus 1324, where the cement slurry as the
shape memory members expand due to exposure to a activation, such
as exposure to an appropriate temperature, e.g but not limited to a
temperature greater than the shape memory members' glass transition
temperature ("GTT"). For example, and not by way of limitation of
the scope of the present invention, shape memory members are first
heated to a temperature above the shape memory members' GTT and
compressed to a first shape and then cooled to retain the
compressed shape. An exemplary GTT of the shape memory members is
about 150 degrees F.
[0130] In one aspect, the compressed shape memory members are then
added to a cement slurry proximate the surface 1310, wherein the
cement slurry and shape memory members are maintained at a desired
temperature, e.g. but not limited to less than about 130 degrees
F., such as about 100 degrees F.
[0131] The cement slurry and the shape memory members are then
directed into the desired location, such as annulus 1324, by the
pump 1322, between the tubular 1306 and borehole 1302 wall. In one
embodiment, the temperature of formation 1304 and borehole 1302 is
higher than the shape memory member GTT, and thus causes the shape
memory members to expand to a second expanded shape. Thus, a
downhole treatment, such as by heating or exposing to an activating
agent, causes the shape memory members to expand, e.g. but not
limited to for filling cracks that may form in the cement during
hydrating and/or hardening. Exemplary borehole 1302 temperatures
include a temperature about equal to or greater than 150 degrees
F.
[0132] After being directed to a selected location in the borehole
1302, the shape memory members expand during hardening of the
slurry, e.g., but not limited to, to reduce development of cracks
in the hydrating cement thereby preventing flow of formation fluid
into the annulus 1324. Further, the shape memory members can expand
within the cement slurry to conform the slurry as it hardens or
sets to contours of the borehole 1302 walls. Thus, the shape memory
members, in certain aspects, added to the cement slurry can improve
sealing and isolation of selected cemented areas of the borehole
102.
[0133] In addition, in certain embodiments, the shape memory
members can cause a reduction in density.
[0134] FIGS. 14A and 14B are views of exemplary embodiments of a
shape memory member 1330 to be added to a cement slurry, as
discussed above. The depicted shape memory member 1330 is
spherical, but it should be understood that the members may be any
suitable shape. The shape memory member 1330 comprises a shape
memory material, such as, but not limited to a shape memory
polymer. Nanomaterial 1336 (not shown to scale in this Figure nor
in FIGS. 14B-15D) is within the shape memory member 1330.
[0135] FIG. 14A illustrates the shape memory member 200 in a
compacted shape; in one aspect, the shape memory member 1330 is
compacted at a temperature at or above a GTT of the shape memory
material, then cooled below the GTT. The compacted shape memory
material has a diameter 1332. The depicted shape memory member 1330
is added to a cement slurry and directed downhole, as described
above.
[0136] FIG. 14B illustrates the shape memory member 1330 in an
expanded shape, wherein the shape memory material is heated so that
it expands. In one particular aspect, it is heated to a temperature
about equal to or greater than the GTT of the shape memory
material. After being directed downhole and into the annulus 1324,
the shape memory member 1330 is heated to a desired
temperature.
[0137] The depicted shape memory member 1330 has a diameter 1334
when expanded, wherein the diameter 1334 is greater than diameter
1332. For other shapes, a largest dimension of the member is
greater after heating.
[0138] FIG. 15A shows a shaped memory member 1500 according to the
present invention which has therein nanomaterial 1505 (which,
optionally, may be deleted). A coating 1502 on the shaped memory
member 1500 has nanomaterial 1504 therein. Any suitable known
coating with nanomaterial may be used, including, but not limited
to, those disclosed and those referred to in U.S. application Ser.
No. 13/998,093 filed 30 Sep. 2013.
[0139] FIG. 15B shows a shaped memory member 1506 according to the
present invention which has therein nanomaterial 1507 (which,
optionally, may be deleted). An intermittent coating 1508 (which
contains nanomaterial) covers less than the entire surface of the
shaped memory member 1506. Any suitable known coating with
nanomaterial may be used, including, but not limited to, those
disclosed and those referred to in U.S. application Ser. No.
13/998,093 filed 30 Sep. 2013.
[0140] FIG. 15C shows a shaped memory member 1510 according to the
present invention which has therein nanomaterial 1514 (as any
disclosed herein) which, optionally, may be deleted. A partial
coating 1512 (which contains nanomaterial) covers less than the
entire surface of the shaped memory member 1510. Any suitable known
coating with nanomaterial may be used, including, but not limited
to, those disclosed and those referred to in U.S. application Ser.
No. 13/998,093 filed 30 Sep. 2013.
[0141] It is within the scope of the present invention to coat all
or part of a shape memory member (containing nanomaterial or not)
with a coating with nanomaterial therein (e.g., but not limited to,
as shown in FIGS. 15A-15D. Such a coating may facilitate the
heating of a shape memory member. Such a coating may strengthen a
shape memory member. Such a coating may assist desired expansion of
a shape memory member. Such a coating may facilitate expansion of a
memory member so that it does not expand uniformly or regularly,
but rather expands nonuniformly and/or nonregularly, producing
instead of a smooth regular shape (such as, e.g., a uniform sphere
or a uniform ovoid or cylinder) an irregular shape, a non-smooth
shape, or both.
[0142] FIG. 15C shows a shape memory member 1510, optionally with
nanomaterial 1514 therein, which has a coating with nanomaterial
1512 which does not cover all the surface of the shape memory
member 1510. FIG. 15D shows the shape memory member 1510 after
expansion (due to heat, contact with appropriate fluids or
materials, or both-- as may be true for any shape memory member
herein). The coating 1512 has separated into separate portions and
the shape memory member 1510 has expanded into an irregular
shape.
[0143] It is within the scope of the present invention to provide
cement compositions with nanomaterial therein, any nanomaterial
disclosed herein; and, in certain aspects, such compositions with
biowaste ash which are improved versions of those disclosed in U.S.
Pat. No. 8,733,440 (incorporated fully herein for all purposes).
Examples of suitable biowaste ash include agricultural waste ash,
municipal waste ash, waste-water treatment waste ash, animal waste
ash, non-human-non-animal industrial waste ash, and combinations
thereof. The cement composition may include any suitable cement,
e.g., but not limited to, known cements used in wellbores, Portland
cement, a pozzolana cement, a gypsum cement, a high-alumina-content
cement, a slag cement, a silica cement, and combinations
thereof.
[0144] In certain aspects, such compositions are used in a method
of well cementing including: introducing a cement composition
according to the present invention into an annulus between a
subterranean formation and a pipe string disposed in the
subterranean formation, wherein the cement composition is, e.g., an
hydraulic cement including at least one cement which is one of a
Portland cement, a pozzolana cement, a gypsum cement, a
high-alumina-content cement, a slag cement, a silica cement, and
combinations thereof, water in an amount sufficient to form a
pumpable slurry, e.g. in some aspects present between about 40% to
about 200% by weight of the cementitious components; and,
optionally, biowaste ash; and optionally biowaste ash that does not
include fly ash or rice hull ash; and allowing the cement
composition to set. Optionally, the nanomaterial in the composition
is used to facilitate setting of the cement due to enhanced thermal
transfer and/or the nanomaterial increases strength of the
cement.
[0145] Such a cement composition according to the present invention
may have nanomaterial present at any desired loading level,
including those disclosed herein. Such a composition may include at
least one additive, e.g., one of a strength-retrogression additive,
a set accelerator, a set retarder, a weighting agent, a lightweight
additive, a gas-generating additive, a mechanical property
enhancing additive, a lost-circulation material, a filtration
control additive, a dispersant, a fluid loss control additive, a
defoaming agent, a foaming agent, a thixotropic additive,
oil-swellable materials, water-swellable materials, crystalline
silica, amorphous silica, fumed silica, a salt, fiber, hydratable
clay, calcined shale, a microsphere, pumicite, diatomaceous earth,
an elastomer, a resin, latex, and combinations thereof (as may any
cement or composition disclosed herein).
[0146] It is within the scope of the present invention to provide a
tubular, a coating for a tubular, and a system including: a tubular
containing a first surface including a coating made of a first
swellable material (optionally with nanomaterial therein) coating
the first surface, the coating having a second surface and the
first swellable material comprising a selectively swellable
material, the first swellable material able to swell in response to
a property change, a temperature change, upon contact with an agent
that induces swelling, or upon coming in contact with a first fluid
on the second surface; and a composition made of a settable
material (with or without nanomaterial therein) and a second
swellable material (with or without nanomaterial therein) able to
swell in swell in response to a property change, a temperature
change, upon contact with an agent that induces swelling, or upon
coming in contact with a second fluid on the second surface. Such a
coating, such a tubular, and such a system according to the present
invention are improvements over these things as disclosed in U.S.
Pat. No. 8,689,894 which is incorporated fully herein for all
purposes.
[0147] In certain aspects, the present invention provides materials
and methods using them for reducing or eliminating wellbore zonal
isolation problems by providing a reliable annular seal between a
formation and a casing, using a swellable material (with or without
nanomaterial therein) associated with an adaptive settable material
(with or without nanomaterial therein). In certain aspects, the
coating for a tubular is flexible swellable material with
nanomaterial therein which is able to dissipate or distribute a
stress load from a tubular, decreasing stress on settable material
adjacent the tubular. Such a coating can be on an inner surface of
a tubular, on an outer surface, or both.
[0148] FIG. 16A shows one aspect of the invention, a system 1610 is
disclosed which has the association of a flexible swellable coating
attached to a tubular 1600 and of an adaptive cement or more
generally to a settable material with a second swellable material.
The tubular 1600 having an internal surface 1612 and an outer
surface 1611. The tubular 1600 is shown as substantially
cylindrical with a flow channel therethrough, but any suitable
shape and configuration tubular may be within the scope of this
invention. The tubular shown is hollow, but it may be solid for
other uses and embodiments.
[0149] The tubular comprises a coating 1602 made of a first
swellable material 1603 able to swell in response to a selected
stimulus or agent, e.g., but not limited to, in response to heat
and/or in response to contact with a first fluid 1606. The coating
1602 has an internal surface 1622 and an outer surface 1621. The
coating is shown as substantially cylindrical, but it may be any
desired shape, dimensions, and/or configuration; and the coating
may be securely attached to the outer surface of the tubular 1600
via the inner surface of the coating 1622. Attachment can be made
by any structure, fastener, or type of system: e.g., glue, hot
melting, hot vulcanization, screwing, interlocking, etc.
[0150] The first fluid 1606 may be any type of suitable fluid,
which may be liquid or gaseous or multi-phasic. In certain aspects,
the fluid is aqueous or non-aqueous e.g. water, oil or
hydrocarbon-based fluids, solvents, gases, fluids from the
formation, wellbore fluids, drilling fluids, fluids pumped from
surface or a combination thereof. The first swellable material is
able to swell in response to an agent, a property change, and/or
upon contact with the first fluid 1606. Swellable materials means
as defined, that the material can swell, i.e. increases its volume
or its apparent volume, e.g., but not limited to, like a sponge. In
certain aspects, the first swellable material remains in a swollen
state when still subjected to first fluid.
[0151] The coating is, in certain aspects, entirely made of a
uniform layer of swellable material coating the tubular, with any
desired thickness and can be any coating disclosed or referred to
herein; e.g., but not limited to, between 0.2 millimeters and 10
Centimeters or as thick as any coating disclosed in U.S.
application Ser. No. 13/998,093 filed 30 Sep. 2013. The coating may
be flexible. By flexible it is meant that the coating has an
elasticity allowing a deformation of the geometry when subjected to
rolling, folding, stress or tension. In certain aspects, it is able
to dissipate anr/or distribute a stress load from the tubular
thereby decreasing stresses on the settable material. In certain
aspects, the risk of crack formation is reduced by the presence of
a flexible coating around the tubular, its role being to spread the
stress load applied on settable material adjacent the tubular; and
crack formation in the set material is eliminated or reduced.
[0152] The material of the coating may be made of a water-swellable
elastomer, a hydrocarbon-swellable elastomer, a gas-swellable
elastomer or a combination of both. It may be made of a composite
material and comprise further other materials. For example, it may
include fillers. The fillers may be water-swellable, gas-swellable,
oil-swellable or swellable to both oil and water or/and gas.
Suitable water-swellable materials include acrylic acid type
polymers, carboxymethyl cellulose type polymers, highly swelling
clay minerals, isobutylene maleic anhydride, polyethylene oxide
polymers, polyvinyl alcohol cyclic acid anhydride graft copolymer,
sodium bentonite (montmorillonite), starch polyacrylate acid graft
copolymer, starch polyacrylonitrile graft copolymers, vinyl
acetate-acrylate copolymers, and combinations thereof.
[0153] Suitable hydrocarbon-swellable (oil and/or gas) materials
include natural rubber, polyisoprene rubber, vinyl acetate rubber,
polychloroprene rubber, acrylonitrile butadiene rubber,
hydrogenated acrylonitrile butadiene rubber, ethylene propylene
diene monomer, ethylene propylene monomer rubber, polynorbornen,
styrene butadiene rubber, styrene/propylene/diene monomer,
brominated poly(isobutylene-co-4-methylstyrene) (BIMS), butyl
rubber, chlorosulphonated polyethylenes, polyacrylate rubber,
polyurethane, silicone rubber, brominated butyl rubber, chlorinated
butyl rubber, chlorinated polyethylene, epichlorohydrin ethylene
oxide copolymer, ethylene acrylate rubber, ethylene propylene diene
terpolymer rubber, sulphonated polyethylene, fluoro silicone
rubbers, fluoroelastomer, substituted styrene acrylate copolymer,
and combinations thereof.
[0154] As shown in FIG. 16A, a composition 1620 in contact with the
tubular or adjacent thereto, is made of a settable material 1605
and a second swellable material 1604. The second swellable material
1604 is able to swell in response to an agent, in response to a
property change, or upon contact with a second fluid 1607. In
certain aspects, the second swellable material remains in a swollen
state when still subjected to the second fluid.
[0155] The second fluid 1607 may be any type of fluid, which may be
liquid or gaseous or multi-phasic. The first and the second fluids
can be the same, or different. In certain aspects, the second fluid
is aqueous or non-aqueous e.g. water, oil or hydrocarbon-based
fluids or a combination thereof. In certain aspects, the second
swellable material 1604 is substantially inactive during reaction
of the first fluid 1606 with the first swellable material 1603.
Thus, in certain aspects, there is a delay in activation of the
swellable materials: firstly, the coating 1602 activates and after
the second swellable material activates within the settable
material 1605. Accordingly, the settable material 1605 can be
preferentially set when activation of the second swellable material
1604 occurs.
[0156] The settable material 1605 is any type of material that has
the ability to go from a fluid state to a solid state with time,
temperature, pressure changes, or under any physical or chemical
stimulus. For example, examples of settable material are: cement,
geopolymer, plaster, resin. In certain aspedts, the settable
material is a cementing composition 1630 comprising an hydraulic
binder, in general based on a suitable cement, e.g. a Portland
cement (or another type of hydraulic material) and water. Depending
on the specifications regarding the conditions for use, the
cementing compositions can also be optimized by adding additives
common to cementing compositions such as dispersing agents,
anti-foaming agents, expansion agents (for example calcium oxide or
magnesium oxide), fluid loss control agents, gas migration control
agents, retarders, accelerators or still anti-settling agents, or
additives of the type. In certain aspects, formulations are based
on Portland cement in classes A, B, C, G and H as defined by
ISO/API standards; and Classes G and H Portland cements may be
used, as well as other cements which are known in this technology
area. For low temperature applications, aluminous cements and
Portland/plaster mixtures or cement silica mixtures for wells
exceeding 120.degree. C. can be used.
[0157] The second swellable material 1604 is able to swell in
contact with the second fluid 1607. As disclosed previously, when
the settable material is cement, the second swellable material 1604
may be rubber, in particular styrene butadiene rubber and ground
rubber, poly 2,2,1-bicyclo-heptene(polynorbornene), alkylstyrene,
rosslinked substituted vinyl-acrylate copolymers and diatomaceous
earth. Mixtures of two or more of these materials can also be used,
in particular to provide cement that is susceptible to react to a
large variety of ubterranean hydrocarbons. The composition made of
the cement and the second swellable material can also be called an
adaptive cement system. Adaptive cement systems refers to cement
systems which are self-healing or self-repairing, i.e. systems
which can adapt to compensate for changes or faults in the physical
structure of the cement, or which adapt their structure in the
cementing of oil, gas, water or geothermal wells, or steam
injection wells or wells with Enhanced Oil Recovery (EOR) or gas
storage wells or the like. In addition to the specific self-healing
additives able to swell in contact with reservoir fluid
(hydrocarbon and/or water), the second swellable material can be
flexible. In this way, the potential combination of flexibility and
toughness can extend the range of mechanical properties of the
settable system and second swellable material to extreme
conditions.
[0158] In another embodiment, the adaptive cement design can also
contain flexible particles and/or fibers to improve respectively
the flexibility and/or the toughness of the set material.
[0159] It is within the scope of the present invention to provide
nanomaterial, e.g. but not limited to carbon nanotubes, to any
swellable material, coating, and/or settable material used in
systems according to the present invention, e.g. but not limited
to, as in FIGS. 16A and 16B. As shown in FIG. 16A, nanomaterial
1640 (shown by squiggly lines, not to scale) may be dispersed
throughout the coating 1602 in the material 1603 (only a few
squiggly lines shown which indicate nanomaterial througOut the
coating and the material) nanomaterial 1641 throughout the settable
material 1605; and/or nanomaterial 1643 throughout the swellable
material 1604. The nanomaterial may be any suitable known
nanomaterial, including but not limited to, those disclosed herein,
at any loading level disclosed or referred to herein. In certain
particular aspects, there is sufficient nanomaterial 1640, 1641,
and/or 1642 present to facilitate swelling of the swellable
material, setting of settable material, and/or to facilitate the
conveyance of heat to the settable material in contact with or
adjacent the tubular and/or to facilitate heating of earth
1609.
[0160] The tubular, e.g. the tubular in FIGS. 16A and 16B, may be a
casing in a wellbore and the settable material may be cement
cementing the casing in the wellbore. The material 1630 may be a
cement slurry pumped down an annulus between the casing and the
wellbore.
[0161] Methods according to the present invention using swellable
material according to the present invention and/or settable
material according to the present invention may be used for various
types of applications: e.g., primary cementing, steam injection,
Steam Assisted Gravity Drainage (SAGD), plug and abandonment,
geothermal wells, gas storage well, and heavy oil applications.
[0162] In conclusion, therefore, it is seen that the present
invention and the embodiments disclosed herein and those covered by
the appended claims are well adapted to carry out the objectives
and obtain the ends set forth. Certain changes can be made in the
subject matter without departing from the spirit and the scope of
this invention. It is realized that changes are possible within the
scope of this invention and it is further intended that each
element or step recited in any of the following claims is to be
understood as referring to the step literally and/or to all
equivalent elements or steps. The following claims are intended to
cover the invention as broadly as legally possible in whatever form
it may be utilized. The invention claimed herein is new and novel
in accordance with 35 U.S.C. .sctn.102 and satisfies the conditions
for patentability in .sctn.102. The invention claimed herein is not
obvious in accordance with 35 U.S.C. .sctn.103 and satisfies the
conditions for patentability in .sctn.103. The prior text of this
specification is in accordance with the requirements of 35 U.S.C.
.sctn.112. The inventor may rely on the Doctrine of Equivalents to
determine and assess the scope of their invention and of the claims
that follow as they may pertain to apparatus and/or methods not
materially departing from, but outside of, the literal scope of the
invention as set forth in the following claims. All patents and
applications identified herein are incorporated fully herein for
all purposes. It is the express intention of the applicant not to
invoke 35 U.S.C. .sctn.112, paragraph 6 for any limitations of any
of the claims herein, except for those in which the claim expressly
uses the words `means for` together with an associated function. In
this patent document, the word "comprising" is used in its
non-limiting sense to mean that items following the word are
included, but items not specifically mentioned are not excluded. A
reference to an element by the indefinite article "a" does not
exclude the possibility that more than one of the element is
present, unless the context clearly requires that there be one and
only one of the elements.
* * * * *