HEAT SOURCES AND ALLOYS FOR USE IN DOWN-HOLE APPLICATIONS

Abstract

A chemical reaction heat source for use in heaters used in down-hole applications is provided. The heat source has a fuel composition that comprises thermite and a damping agent. The use of the thermite mix enables the heaters of the present invention to generate hotter temperatures down wells. This in turn allows the use of Bismuth/Germanium alloys, which have higher melting points, to enable the production of plugs for the abandonment of deeper wells where subterranean temperatures are higher.

Claims

1-14. (canceled)

15. A Bismuth alloy based plug tool, characterized in that the Bismuth alloy comprises Bismuth and Germanium.

16.-22. (canceled)

23. A downhole tool comprising: (a) a heating element comprising a mixture of: (i) a chemical reaction heat source; and (ii) a damping agent; wherein the mixture defines a ratio of the chemical reaction heat source and the damping agent, wherein the ratio is selected to provide a predetermined temperature upon activation of the heating element; and, (b) a plug material comprising an alloy, the alloy having a predetermined melting temperature; (c) wherein the predetermined temperature is based upon the predetermined melting point, wherein the predetermined melting temperature is based upon the predetermined temperature, or both.

24. The downhole tool of claim 23, wherein the alloy comprises bismuth.

25. The downhole tool of claim 23, wherein the alloy comprises germanium.

26. The downhole tool of claim 23, wherein the alloy comprises germanium and bismuth.

27. The downhole tool of claim 23 or 24, wherein the alloy comprises no more than about 20% germanium by weight.

28. The downhole tool of claim 23 or 24, wherein the alloy comprises no more than about 1% germanium by weight.

29. The downhole tool of claim 23, 24, or 25, wherein the alloy comprises copper.

30. The downhole tool of claim 23, 24, or 25 wherein the chemical reaction heat source comprises thermite.

31. The downhole tool of claim 23, 24, or 25 wherein the dampening agent comprises sand.

32. The downhole tool of claim 23, 24, or 25 wherein the predetermined temperature upon activation is 600° C.

33. The downhole tool of claim 23, 24, or 25 wherein the predetermined melting temperature is from about 271° C. to about 938° C.

34. A downhole tool system comprising: (a) a heating element comprising a mixture of: (i) a chemical reaction heat source; and (ii) a damping agent; wherein the mixture defines a ratio of the chemical reaction heat source and the damping agent, wherein the ratio is selected to provide a predetermined temperature upon activation of the heating element; and, (b) a plug material in a well, the plug material comprising an alloy, the alloy having a predetermined melting temperature; and, (c) wherein the predetermined temperature is based upon the predetermined melting point, wherein the predetermined melting temperature is based upon the predetermined temperature, or both.

35. The downhole tool system of claim 34, wherein the mixture is homogenous.

36. The downhole tool system of claim 34 or 35, wherein the mixture is a solid.

37. The downhole tool of claim 23, wherein the mixture is homogenous.

38. The downhole tool od claim 37, wherein the mixture is a solid.

39. The method of using the downhole tool of claim 1 for a downhole application in a well.

40. The method of claim 41, wherein the downhole application, comprises an application selected from the group consisting of squeezing off, the fitting of annulus packers, the repair of annulus packers, the maintenance of sand filters, and the repair of sand filters.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The present invention will now be described with reference to the drawings, wherein:

[0039] FIG. 1 shows an arrangement of heating blocks suitable for a plug deployment heater;

[0040] FIG. 2 shows an arrangement of heating blocks suitable for a plug retrieval heater;

[0041] FIG. 3 shows a phase diagram for various mixes of Bismuth/Germanium alloys.

DESCRIPTION OF THE VARIOUS ASPECTS OF THE PRESENT INVENTION

[0042] It is envisaged that the various aspects of the present invention can be use alone or in combination with one another to provide real benefits in the plugging of underground conduits. It is envisaged that although the present invention is particularly applicable in plugging both vertical and non-vertical wells (with or without well casings) the heaters of the present invention have characteristics which make that suitable for a range of other down-hole applications.

[0043] For example the described aspects can be used together with the methods and apparatus described in WO2011/151271 to facilitated the squeezing off and repairing of wells.

[0044] Whilst the various aspects of the present invention are considered particularly applicable to the plugging of oil and gas wells it is envisaged that they would provide benefits when plugging other forms of underground conduits such as water pipes for example.

[0045] In a preferred embodiment of the chemical reaction heat source of the present invention the fuel composition is provided in the form of a stacked arrangement of blocks that, in use, are housed within a heater body. Each block is capable of generating a certain level of heat, the level of which is predetermined by the ratio of thermite to damping agent (e.g. sand) in the composition mix of that particular block.

[0046] It is envisioned that a range of predetermined mixes, which are capable of generating a range of predetermined temperatures, are produced by varying the levels of thermite from 99% to 1% by mixing the thermite with a damping agent. The damping agents (or combustion suppressing agents as it may also be referred to herein) preferably take the form of silica or sand. However it is envisioned that alternative forms of damping agent may also be adopted without departing from the general inventive concept of the present invention.

[0047] It is appreciated that by arranging blocks with differing heating abilities in specific stacking orders it is possible to create a chemical reaction heat source that generates a heating pattern appropriate to the type of heater it is being used in.

[0048] FIGS. 1 and 2 each show an example of a chemical reaction heat source, 10 and 50, with a block stacking arrangement that creates a distinct heating pattern.

[0049] For the ease of understanding the heating power of each block has been assigned a number from 0 to 5, wherein 0 burns faster and therefore hotter and 5 burns slower and therefore cooler. Although the ratio of thermite to damper agent in each point of the scale is not specifically identified herein it is envisioned that the hottest level 0 may be provided by almost pure thermite. The coolest level (i.e. 5) may be provided by a mix predominately made from a damping agent (e.g. sand).

[0050] It will be appreciated that the ratios of the mixes used to achieve the heating powers of 1 to 4, for example, will therefore vary between the two end points set by the mixes of heating power 0 and heating power 5.

[0051] In both of the examples shown the region 20 nearest to the igniter 30 (shown as 0) has the highest level of thermite (virtually 100%) so as to ensure that the chemical reaction gets off to the best start. It is envisioned that, due to the potency of the pure thermite, the starter block may be smaller than the other blocks in the stack.

[0052] Although not shown it is also appreciated that pure thermite powder may be provided in and around the region where the igniter and the first block come into contact. In this way the chemical reaction is given the best chance of being successfully initiated.

[0053] FIG. 1 shows a diagram of an arrangement of fuel composition blocks 1 that provides a chemical reaction heat source that is particularly suited to a heater for deploying Bismuth-based plugs such as those described in WO2011/151271.

[0054] The arrangement shown in FIG. 1, which arranges the faster/hotter reacting blocks in the middle of the stack, is particularly suited to the task of deploying a Bismuth-based plug because the main focus of the heat in the heating pattern 40 is the middle of the heater, which, when the heater is engaged with a plug, is aligned to the location of un-melted alloy.

[0055] In addition, the provision of the coolest block at the base of the stack helps to direct the heat away from the base of the heater. This is important because this is the area where the melted alloy will start to cool down and expand against the sides of an underground conduit to form the required plug. Thus shielding this region from the heat source is advantageous.

[0056] Although not shown in the figures, it is envisaged that pure damping agent may be provided at the base of the heater stack shown in FIG. 1 to further shield the base region of the heater and the corresponding region of a plug.

[0057] FIG. 2 shows a diagram of an arrangement of fuel composition blocks 50 that provides a chemical reaction heat source that is particularly suited to a heater for retrieving Bismuth-based plugs such as those also described in WO2011/151271.

[0058] The arrangement 50 shown in FIG. 2, which arranges the faster and hotter reacting blocks (e.g. heating power 1) towards the bottom of the stack, is particularly suited to the task of retrieving a Bismuth-based plug that is in-situ within a well because the main focus of the heat 60 is towards the base of the heater, which, when the heater is engaged with a plug, is aligned the location of alloy plug.

[0059] It will be appreciated that the present invention allows the heating characteristics of a given heater to be fine-tuned to better suit the particular needs of any given down-hole task by effectively adjusting the arrangement blocks to achieve the most appropriate heating pattern.

[0060] In view of this the present invention also provides a method of tailoring a well abandonment system (i.e. a heater) to suit a particular underground conduit or well.

[0061] This method essentially comprises:

[0062] a) assessing the down-hole environmental characteristics of the underground conduit or well that is to be plugged;

[0063] b) selecting a Bismuth alloy suitable to produce a stable plug within the environment of the underground conduit or well;

[0064] c) providing a chemical reaction heat source suitable to melt the selected Bismuth alloy, said heat source having a fuel composition that comprises thermite and a damping agent;

[0065] d) producing a tailored well abandonment system comprising the selected Bismuth alloy and provided chemical reaction heat source.

[0066] It is appreciated that there are a range of down-hole environmental characteristics that may have a bearing on what type of heater and/or plug is required for the job. Some of the most relevant characteristics are: [0067] 1) Temperature in the region of the underground conduit where the plug is to be deployed; [0068] 2) Pressure in the region of the underground conduit where the plug is to be deployed; [0069] 3) Differential pressure requirement of the plug, now and in the future; [0070] 4) Well bore fluid; [0071] 5) Well completion characteristics.

[0072] It is envisioned that Bismuth/Germanium alloys may be adopted due to the enhanced heating capabilities realised by the thermite-based heat sources of the present invention.

[0073] FIG. 3 shows how the melting temperature of an alloy can be controlled by varying the ratio of Bismuth to Germanium in the alloy. It will be appreciated from the data shown that the introduction of Germanium has a marked effect on the melting temperature up to about 20% by weight, after which the temperature increasing effects are less marked.

[0074] The present invention also provides for a method of tailoring a plug retrieval heater system that involves assessing the nature of the alloy of the plug that is to be retrieved from the underground conduit and then providing a chemical reaction heat source suitable to melt the alloy, said heat source having a fuel composition that comprises thermite and a damping agent.