Downhole tool deployment assembly with improved heater removability and methods of employing such

Abstract

The present invention provides a downhole tool deployment assembly (1) for use in particular in oil/gas wells. The assembly comprises a heater (2) with a tubular heater body having an internal cavity configured to receive a heat source (6). The assembly also has a tubular heat conducting member (3) configured to surround the tubular heater body leaving an annular clearance, wherein the tubular heat conducting member does not extend along the entire length of the tubular heater body. In addition, a collar (4) is mounted adjacent to the region of the assembly where the tubular heat conducting member ends. The collar is configured to prevent access to the annular clearance between the tubular heat conducting member and the tubular heater body. A eutectic/bismuth based alloy (5) covers the collar and at least a portion of the tubular heater body and the tubular heat conducting member such that the alloy holds the heater and the tubular heat conducting member together until the alloy is melted.

Claims

1. A downhole tool deployment assembly, said assembly comprising: a heater with a tubular heater body having an internal cavity configured to receive a heat source; a tubular heat conducting member configured to surround the tubular heater body leaving an annular clearance between said conducting member and said heater body, wherein the tubular heat conducting member does not extend along the entire length of the tubular heater body; a collar mounted adjacent to the region of the assembly where the tubular heat conducting member ends, wherein the collar is configured to prevent access to the annular clearance between the tubular heat conducting member and the tubular heater body; an eutectic/bismuth based alloy covering extending over the collar and at least a portion of the tubular heater body and the tubular heat conducting member, and whereby only the alloy holds the heater and the tubular heat conducting member together until the alloy is melted; and whereby once the eutectic/bismuth based alloy has melted and slumped, the heater can be retrieved from the heat conducting member through said clearance.

2. The assembly of claim 1, wherein the collar is mounted on the tubular heater body.

3. The assembly of claim 1, wherein the collar extends from a first diameter at a first end thereof to a second, larger diameter at a second end thereof.

4. The assembly of claim 1, wherein the alloy is at least partially enclosed within an insulating sleeve.

5. The assembly of claim 4, wherein the insulating sleeve comprises one or more openings in a region adjacent to the collar.

6. The assembly of claim 4, wherein the insulating sleeve comprises one or more weakened points in the region adjacent to the collar; said weakened points being configured to fail before the rest of the remaining sleeve.

7. A method of deploying a downhole tool within an oil/gas well, said method comprising: delivering into a target region of an oil/gas well a tool deployment assembly according to claim 1; activating the heater to melt the eutectic/bismuth alloy layer; allowing the alloy to cool and secure the tubular heat conducting member in position within the oil/gas well to form the downhole tool; retrieving the heater from the oil/gas well.

8. A downhole tool deployment assembly, said assembly comprising: a heater with a tubular heater body having an internal cavity configured to receive a heat source, wherein the tubular heater body comprises an up-hole section and a downhole section that are separated by a point of weakness; a collar mounted adjacent to the point of weakness, wherein the collar is configured to cover the point of weakness; and a eutectic and/or bismuth based alloy covering extending over the collar and at least a portion of both the up-hole section and the downhole section of the tubular heater body, and whereby the alloy holds the up-hole and downhole sections of the tubular heater body together until the alloy is melted.

9. The assembly of claim 8, wherein the collar extends from a first diameter at a first end thereof to a second, larger diameter at a second end thereof.

10. The assembly of claim 8, wherein the alloy is at least partially enclosed within an insulating sleeve.

11. The assembly of claim 10, wherein the insulating sleeve comprises one or more openings in a region adjacent to the collar.

12. The assembly of claim 10, wherein the insulating sleeve comprises one or more weakened points in the region adjacent to the collar; said weakened points being configured to fail before the rest of the insulating sleeve.

13. A method of deploying a downhole tool within an oil/gas well, said method comprising: delivering into a target region of an oil/gas well a tool deployment assembly according to claim 8; activating the heater to melt the eutectic/bismuth alloy layer; allowing the alloy to cool and secure the downhole section of the tubular heating body in position within the oil/gas well to form the downhole tool; retrieving the up-hole section of the tubular heater body from the oil/gas well.

14. The assembly of claim 1, 2, 3 or 4, wherein the tubular heat conducting member is formed from aluminum.

15. The assembly of claim 1, 2, 3 or 4 further comprising a skirt portion located at the end of the tubular heat conducting member remote from the collar.

16. The assembly of claim 1, 2, 3 or 4 further comprising an end plate located at the end of the tubular heat conducting member remote from the collar.

17. The assembly of claim 1, 2, 3 or 4, further comprising releasable fixing means to supplement the holding together of the heater and the tubular heat conducting member until the alloy is melted.

18. The assembly of claim 1, 2, 3 or 4, wherein the internal cavity of the tubular heater body contains a chemical reaction heat source.

19. The assembly of claim 1, 2, 3 or 4, wherein the inner walls of the tubular heater body are provided with a layer of refractory material.

20. A method of deploying a by-pass conduit, such as a straddle, within an oil/gas well, said method comprising: deploying a downhole tool within an oil/gas well using the method of claim 7 or 13; providing a length of tubing with eutectic/bismuth based alloy mounted on the outer wall of said tubing; delivering the tubing onto the downhole tool; heating the tubing so as to melt said alloy; and allowing the eutectic/bismuth based alloy to cool and secure the tubing in position so as to form a by-pass conduit within the oil/gas well.

21. The method of claim 20, wherein the alloy provided on the tubing is in the form of an annular packer.

22. The method of claim 20, wherein the tubing is heated using a heater located within the tubing.

23. The method of claim 22, wherein the heater comprises a chemical heat source.

24. The method of any of claims 21 or 22, wherein the heater is retrieved once the alloy has cooled.

25. The method of claim 20 wherein the heater is retrieved once the alloy has cooled.

26. A method of sealing an oil/gas well, said method comprising: delivering into a target region of an oil/gas well a tool deployment assembly according to claim 1 or 8; activating the heater to melt the eutectic/bismuth alloy layer; allowing the alloy to cool and secure the downhole section of the tubular heating body in position within the oil/gas well to form a seal within the target region; retrieving the up-hole section of the tubular heater body from the oil/gas well.

27. The assembly of claim 8, 9, or 11, further comprising a skirt portion located at the end of the tubular heat conducting member remote from the collar.

28. The assembly of claim 8, 10, or 12, further comprising an end plate located at the end of the downhole tubular section remote from the collar.

29. The assembly of claim 8, 9, or 10, further comprising releasable fixing means to supplement the holding together of the up-hole and downhole sections of the tubular heater until the alloy is melted.

30. The assembly of claim 8, 11, or 12, wherein the internal cavity of the tubular heater body formed by the up-hole and downhole sections contains a chemical reaction heat source.

31. The assembly of claim 8, 9, or 10, wherein the inner walls of the up-hole and downhole sections of the tubular heater body are provided with a layer of refractory material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The various aspects of the present invention will now be described with reference to preferred embodiments shown in the drawings, wherein:

(2) FIG. 1 shows a partially exposed view of a preferred embodiment of a downhole tool deployment assembly of a first aspect of the present invention engaged with running tool; and

(3) FIG. 2 provides a diagrammatic representation of the key stages of deploying a downhole tool in well tubing using the downhole tool deployment assembly of the first aspect of the present invention;

(4) FIG. 3 is a diagrammatic representation of the key stages of deploying a straddle in an open hole gravel pack (OHGP) using the downhole tool deployment assembly of the first aspect of the present invention; and

(5) FIG. 4 provides a diagrammatic representation of the key stages of deploying a downhole tool in well tubing using the downhole tool deployment assembly of the second aspect of the present invention.

DETAILED DESCRIPTION OF THE VARIOUS ASPECTS OF THE PRESENT INVENTION

(6) The downhole tool deployment assembly of the present invention disclosed herein is considered particularly suitable for use in downhole operations that take place within gas and oil wells. In particular, the well tool deployed in accordance with the present invention is considered particularly suitable for use in repair operations involving Open Hole Gravel Packs.

(7) The term ‘Open Hole Gravel Pack’ (OHGP) is used throughout to indicate when a screen is used to hold back proppant/sand in a completion. It will be appreciated that, in practise, this covers all gravel pack completions including open hole, cased hole and frac packs.

(8) Although the sealing and repair of Open Hole Gravel Pack is considered a particular suitable application of the present invention, it is envisioned that the downhole tool deployment assembly of the present invention can also be employed in other well repair operations, as well as in well abandonment.

(9) Given the main focus of the present invention, the preferred embodiments will be described with oil and gas wells in mind. However, it is envisioned that the apparatus and methods described could be usefully applied in other technical fields, such as those fields where underground conduits are to be plugged (e.g. water pipes).

(10) The main components of the downhole tool deployment assembly of the present invention are shown in FIG. 1, which provides a partially exposed view of a preferred embodiment of the assembly 1.

(11) The assembly 1 is constructed from a heater with a tubular heater body 2, at least a portion of which is received within a tubular heat conducting member 3. Unlike previous downhole tool deployment assemblies, the tubular member 3 that is positioned on the outside of the tubular heater body 2 only receives a portion of the heater body. As a result, a significant portion of the heater body is exposed and is not surrounded by the tubular member 3.

(12) Although not essential, it is envisaged that the assembly of the present invention is particularly suited to chemical heat source based heating, using for example thermite-based heat sources. The chemical heat source material is housed within the internal cavity of the tubular heater body 2. In the preferred embodiment, the chemical heat source material is provided in the form of a plurality of thermite blocks 6.

(13) Also, although not shown it is envisaged that additional benefits may be gained by providing a refractory layer or coating between the chemical heat source material and the heater tubular body. The benefits of providing a refractory coating are discussed above.

(14) This partial covering of the tubular heater body 2 distinguishes the assembly of the present invention from downhole tool deployment assemblies of the past, in which the heaters were either entirely received within an outer tubular member or there was no outer tubular member at all provided.

(15) It will be appreciated that in those downhole tool deployment assemblies where no outer tubular member is present, the alloy is provided directly onto the heater body rather than on an intermediate tubular body.

(16) The arrangement of the downhole tool deployment assembly of the present invention is such that the weight of the assembly is reduced by essentially removing a significant portion of the tubular member 3, which would have otherwise been present if the entire length of the tubular heater body 2 was to be received.

(17) The omission of a portion of the tubular member 3 serves to create more space to accommodate the eutectic/bismuth based alloy, which is provided on the outside of the assembly without necessarily increasing the profile (i.e. external diameter) of the assembly.

(18) By way of some context, previously the addition of more alloy to the assembly would have resulted in the assembly being made longer and/or fatter (i.e. increased diameter).

(19) In some situations the shape of the target well can impose a maximum limit on one or more of these dimensions. It is on these occasions that assemblies without an intermediate tubular member (i.e. alloy provided directly on heater) might have been deployed. As detailed above, however, this approach can face difficulties when it is desirable to retrieve the heater from the well after the alloy has cooled and re-solidified due to the heater becoming trapped by the re-solidified alloy.

(20) In view of the above, it will be appreciated that increasing the space available to accommodate alloy on the assembly without increasing the overall profile of the assembly is advantageous. Further, reducing the weight of the assembly can also make it easier to handle above-ground and deploy downhole.

(21) Although in the downhole tool deployment assembly shown in the figures about a third of the tubular heater body 2 is exposed (i.e. not received within tubular member 3), it is envisaged that this ratio may be varied depending on the requirements of a particular task. Ultimately, however, it is a key feature of the present invention that at least a portion of the heater tubular body 2 extends out of the outer tubular member 3.

(22) Preferably, at least 25% of the heater tubular body 2 must be received within the outer tubular member 3. That is to say, at least 75% of the heater tubular body 2 is exposed and in direct contact with the alloy. However it is envisaged that the extent to which the heater tubular body 2 is received within the outer tubular member 3 will depend on the outer diameter of the tool and/or the inner diameter of the well bore.

(23) The dimensions of the tubular heater body 2 are such that it can be slideably received within and retrieved from the outer tubular member 3. To this end, there must be a suitable clearance, preferably around 1 mm, between the outer diameter of the tubular heater body 2 and the inner diameter of the tubular member 3.

(24) Once received within the tubular member 3, the tubular heater body 2 is held in place by an outer coating of eutectic/bismuth based alloy 5. This arrangement ensures that the tubular heater body can only be removed from the tubular member 3 once the alloy 5 has been melted.

(25) Although not shown, it is envisaged that addition temporary fixing means may be provided to supplement and support the connection of the tubular heater body 2 to the outer tubular member 3. Such additional temporary fixing means may take the form of shear pins or shear rings. However alternatives will be appreciated by the skilled person upon consideration of the invention as a whole.

(26) As can been seen from FIG. 1, the alloy 5 preferably extends along the entire length of the heater body 2. Of course, for at least a portion of that length the alloy 5 is separated from the tubular heater body 2 by the outer tubular member 3.

(27) This co-axial arrangement of the alloy 5 and the tubular heater body 2 ensures that the alloy is effectively heated. In will be understood that the presence of the intermediate tubular member 3 may result in an uneven heating of the alloy along the length of the assembly because some of the alloy is in direct contact with the heater and some of the alloy is not.

(28) Heating uniformity can be achieved by making the outer tubular member 3 from a heat conducting material, such as Aluminium. Other examples include steel alloys. In this way the heat from the heater can readily pass through the intermediate tubing to the alloy.

(29) Alternatively or additionally, uniform heating of the alloy might also be achieved by using a predetermined arrangement of chemical heat source material blocks 6 with varying heat generation characteristics. In this regard, the applicant earlier International PCT filing (Pub. No. WO 2014/096857) deals with the provision of chemical heat sources that can be tailored to create specific heating patterns by stacking blocks with differing mixtures of thermite and damping agent.

(30) In the case of the assembly of the first aspect of the present invention, it is envisaged that the heating blocks located in the exposed portion of the tubular heater body might include an increased proportion of damping agent when compared to the blocks located in the portion of the heater body that is received within the outer tubular member. In this way the exposed heater portion can be configured to emit less heat than the received portion, thereby providing a more uniform heat along the entire length of the alloy.

(31) The tubular heater body 2 is provided with ignition means 11 at the trailing end thereof (i.e. the end that enters the well hole last). The ignition means 11 are inserted into the open end of the tubular heater body 2 and secured in position, preferably using a screw thread arrangement—although other fixing arrangements may be employed.

(32) Once in position, the ignition means 11 is configured to enable the heater, and as a result the assembly 1 as a whole, to a running tool 10. The running tool 10, together with above-ground delivery tools, facilitates the delivery of the assembly 2 down the well hole.

(33) The tubular heater body 2 is closed at the leading end, which is the end opposite where the ignition means 11 is received. This enables the heat source material 6 to be received and housed within the heater tubular body 2.

(34) The tubular member 3 is provided with an end plate 7, which is secured onto the leading end of thereof. The end plate 7 is preferably secured in position by welding; however alternative attachment methods will be appreciated. For example, it is envisaged that the tubular member 3 may be blocked by a burst disk that is held in position by ‘O’ rings or a metal sealing ring. The provision of a burst disk means that the tubular member 3 can be quickly unblocked at a later date to suit the needs of a particular well.

(35) The end plate 7 serves to close off the end of the tubular member 3 such that, once deployed, the combination of the tubular member and the re-solidified alloy form a downhole tool that plugs the well hole.

(36) The end plate 7 is a preferred feature of the tubular member 3. In view of this it is envisaged that in some assemblies, where a plug is not required (i.e. by-pass conduits), the end plate 7 need not be present.

(37) The tubular member 3 is also provided with a skirt portion 8. The skirt portion may be secured to the leading end of the tubular member 3 by a screw thread or by welding. Other attachment mechanisms may also be employed without departing from the general concept of the present invention. The skirt portion is preferably made of high strength steel, although other suitable materials will be envisaged by the skilled person upon consideration of the described invention.

(38) Alternatively, the skirt portion 8 may be formed as part of the tubular member 3. In this arrangement the length of the skirt portion would be determined by the location of the end plate 7 within the tubular member 3.

(39) The role of the skirt portion is to provide a cooler region adjacent the heater where the molten alloy can start to cool and solidify. Cooling is achieved by allowing downhole fluids to get inside the skirt portion 8, whereby the heat energy present in the skirt portion due to the heater can be more quickly transferred away by the downhole fluids.

(40) This cooling of the skirt portion 8 relative to the directly heated region of the tubular member 3 helps to begin the alloy re-solidification process, which helps prevent molten alloy simply dripping off the end of the assembly 1 and falling down the well.

(41) As can be seen from FIG. 1, the eutectic/bismuth based alloy 5 coats a large portion of the assembly, covering most of the exposed heater tubular body 2, the tubular member 3 and the collar 4.

(42) It will be appreciated that the thickness of the alloy 5 coating varies along the length of the assembly 1 to take advantage of the additional space provided by the omission of the tubular member 3 towards the trailing end of the assembly 1. The alloy coating is such that the outer diameter of the assembly remains consistent along the length of the assembly, whilst retaining more alloy that would have been possible if the tubular member 3 extended the entire length of the assembly.

(43) In view of the relatively soft nature of the alloy 5, the assembly is also provided with an anti-crush member 9. The anti-crush member 9, which is formed from a material with greater mechanical strength than the alloy 5 (e.g. steel), is located at the trailing end of the assembly 1 adjacent to open end of the tubular member 3 in to which the ignition means 11 are inserted.

(44) The anti-crush member 9 provides the upper region of the assembly with increased structural strength that enables the assembly to gripped and manoeuvred by mechanical handling equipment above ground without being damaged or deformed.

(45) It will be appreciated from FIG. 1 that the anti-crush member 9 is configured to ensure that the consistent outer diameter of the assembly is maintained. To this end, a reduced thickness of alloy (or possibly no alloy) is provided in the region of the anti-crush member 9.

(46) Although not shown, it is envisaged that the assembly 1 may further be provided with an outer insulating layer or covering that completely encloses the alloy. The insulating layer/covering is preferably provided with openings or weakened regions so as to provide specific egress points for the alloy as it melts. The benefits of providing the outer insulating layer are described above.

(47) The operation of the downhole tool deployment assembly of the first aspect of the present invention will now be described with reference to FIG. 2, which shows the key stages of the downhole tool deployment method.

(48) In the first stage the ignition means 11 is attached to the assembly 1 and then attached to the running tool 10. The running tool 10, which is engaged with a delivery tool (not shown) is then used to deliver the assembly 1 to a downhole target region within a well casing/tubing 12.

(49) Once in position at the target region the ignition means 11 are activated and the chemical reaction of the chemical heat source (e.g. thermite based heat source) is started. The heat given off by the chemical heat source melts the alloy 5 directly, and indirectly via the tubular member 3, causing the alloy to flow. As the alloy 5 flows it is immediately subjected to the cooling influences of the surrounding downhole environment (i.e. downhole fluids), which typically have a temperature range of around 20 to 170° C.

(50) As soon as the alloy 5 flows away from the heat being generated by the chemical heat source it starts to cool and, as it does, re-solidify. This cooling process is further assisted by the provision of the skirt portion 8 at the leading end of the assembly. As will be appreciated, the skirt portion 8 allows the downhole fluids to cool the alloy from both outside and inside the assembly 1.

(51) As will be appreciated from the second stage shown in FIG. 2, the alloy flows away from the exposed portion of the tubular heater body 2 cooling as it flows until it forms any annular alloy seal 5a between the tubular member 3 and the surrounding well casing/tubing 12. The flow of the alloy is such that clearance is achieved between the alloy seal 5a and the exposed portion of the tubular heater body 2. The alloy flow also provides clearance between the collar 4 and the annular alloy seal 5a.

(52) In the final stage, the running tool 10 can be used to extract the tubular heater body 2 from within the tubular member 3 and then retrieve it from the downhole environment.

(53) The formation of the annular alloy seal 5a serves to lock the tubular member 3 in position within the well casing, thereby completing the deployment of the downhole tool.

(54) While the downhole tool (i.e. the tubular member 3 and the alloy 5a) is held in position within the well casing/tubing, the tubular heater body 2 is no longer held securely within the tubular member 3 due to the relocation of the alloy that previously held the tubular heater body 2 and the tubular member 3 together.

(55) With the tubular member 3 held firmly in place and the tubular heater body 2 released, the operation of the running tool 10 readily extracts the tubular heater body so that it can be retrieved from the well casing 12.

(56) If additional fixing means are provided (e.g. shear pins/rings), such will be configured with a break point that is lower than the expected failure level of the alloy plugs, such that the fixing means fail when the heater is retrieved using the delivery tool.

(57) The provision of the collar 4 ensures that no alloy can flow into the gap between the tubular heater body 2 and the outer tubular member 3 and cool, which, it will be appreciated, could seal the tubular heater body 2 and the outer tubular member 3 together and prevent them being readily pulled apart.

(58) The removal of the tubular heater body and the running tool leaves the downhole tool secured in position within the well casing. It is envisaged that, due to the presence of end plate 7 within the tubular member 3, the preferred embodiment of the downhole tool shown in the figures can be used as a permanent or semi-permanent plug.

(59) Alternatively, if the end plate were to be omitted, the downhole tool might instead be used as a platform to support the deployment of a straddle or other by-pass conduit within a target region of a well.

(60) FIG. 3 shows a diagrammatic representation of the key stages of deploying a straddle within an Open Hole Gravel Pack (OHGP) of a well.

(61) In the first stage an operating oil well with an OHGP is shown. An open hole 100 is formed in an underground formation so as to access an underground oil/gas reservoir.

(62) The oil/gas is extracted from the reservoir via the production tubing 101, which in the region of the reservoir comprises a screen with a plurality of slots or apertures designed to allow the free flow of downhole fluids, including oil, into the tubing and ultimately out of the well.

(63) In order to prevent the slots or apertures of the tubing 101 becoming blocked, a proppant 102 is provided between the tubing 101 and the surrounding formation 100.

(64) In the past, in order to form a plug within an OHGP it would be necessary to first perforate the region in order to facilitate the setting of a cement plug. This is because the cement would otherwise not be able to flow through the slots or apertures of the tubing 101 and the surrounding proppant 102.

(65) However, the present invention utilises the distinctive characteristics of eutectic/bismuth based alloys to form plugs in this environment without the need to carry out any perforation processes.

(66) Returning to the first stage of FIG. 3, it can be seen that three different fluid streams are exiting the formation 100 and entering the production tubing 101.

(67) The first stream 103 and the third stream 105 represent a fluid with an acceptable proportion of oil to water. However the second stream 104 represents a fluid with a much higher proportion of water, which is undesirable.

(68) When the streams 103, 105 and 104 combine within the production tubing 101 they produce a combined fluid with a much less commercially acceptable oil to water ratio. In view of this it is highly advantageous to the economic viability of the well if the first fluid stream 103 and the third fluid stream 105 can be isolated from the second fluid stream 104. However the positioning of the second fluid stream source between the first and third fluid stream sources makes it difficult to do this.

(69) The downhole tool deployment assembly of the present invention enables the deployment of a by-pass conduit, such as a straddle, within the production tubing 101 to isolate the non-oil producing fluid stream 104 from the other neighbouring oil producing streams 103 and 105.

(70) Although the straddle tool is not shown in detail in FIG. 3, it should be understood that the straddle is preferably formed from a pair of tool components that are each set in place using the downhole tool deployment assembly of the present invention

(71) In the second key stage shown in FIG. 3 a downhole tool deployment assembly 110 of the present invention is run into the well bore 100 using a wire line 111.

(72) As will be appreciated from the previous descriptions, the assembly 110 comprises a heater body 2 that is partially received within the outer tubular member 3. Unlike in the embodiment shown in FIGS. 1 and 2, however, in this arrangement the outer tubular member is not provided with an end plate. This ensures that the outer tubular member 3 can perform its function as part of the by-pass conduit.

(73) The heater body 2, which it will be appreciated preferably houses a chemical heat source (not shown), is provided with a collar 4.

(74) A eutectic/bismuth based alloy 5 covers the heater body 2, outer tubular member 3 and the collar 4. It is appreciated that the alloy may preferably be at least partially enclosed within an insulating sleeve. However the sleeve has not been included in FIG. 3 to avoid overcomplicating the diagrammatic representation.

(75) Once in position within the production tubing 101, the heater is activated, preferably using a signal transmitted via the wire line 111, and the alloy 5 is melted. As the molten alloy flows away from the heater it begins to cool and re-solidify, thereby causing the formation of an alloy plug 5a within the well bore 100.

(76) Following the formation of the alloy plug 5a, the heater body 2 and the attached collar 5 can be retrieved from the well using the wire line 111. This stage is shown in the third key stage of FIG. 3. It will be appreciated that the second and third key stages of FIG. 3 proceed in accordance with the stages shown in FIG. 2, as described above.

(77) Following the removal of the heater/collar, a second downhole tool deployment assembly 114 can be run down the well into the target region just above the plug 5a. This is shown in the fourth key stage of FIG. 3.

(78) The second downhole tool deployment assembly 114 is similar to the first assembly 110, however it is preferably provided with a length of tubing 115 that extends from the leading end of the outer tubular member 3. It is envisaged that the tubing may be formed as part of the outer tubular member or it may simply be attached to it by standard connection means (i.e. screw threaded engagement).

(79) The leading end of the tubing 115 is provided with means for engaging the trailing end of the outer tubular member 3 of the tool deployed by the first downhole tool deployment assembly 110. It is envisaged that any arrangement that facilitates the alignment of the central cavities of the tubing 115 with the outer tubular member 3 of the tool deployed by the first downhole tool deployment assembly 110 is considered suitable.

(80) Preferably the engagement formed between the tubing 115 and the outer tubular member 3 of the tool deployed by the first downhole tool deployment assembly 110 is fluid tight to ensure that fluid entering the by-pass conduit is transported the full length of the conduit and does not escape via the joint between the two components.

(81) Once the tubing 115 and the outer tubular member 3 of the tool deployed by the first downhole tool deployment assembly 110 are suitably engaged within the well bore, the heater of the second assembly 114 is activated and its associated alloy melted.

(82) As before, the molten alloy will flow away from the heater and cool to form a plug 116 within the well bore. The two plugs 5a and 116 serve to both hold the two tool components of the by-pass conduit together and prevent fluids flowing around the plugs via the proppant 102.

(83) The final stage of FIG. 3 shows the by-pass conduit being held in position by the upper alloy plug 116 and the lower alloy plug 5a. Once in position, the by-pass conduit facilitates the flow of the first 103 and third 105 fluid streams out of the well via the production tubing 101, whilst at the same time isolating the second, undesirable fluid stream 104.

(84) It is envisaged that the tubing 115 of the by-pass conduit shown in FIG. 3 may comprise an expandable tubular member that, in use, is located between the two alloy plugs 5a and 116. In this way, once the plugs have been set within the well, the diameter of the tubing can be expanded to allow for an increased flow rate through the by-pass conduit.

(85) In a further alternative improvement the tubing 115 may be provided with at least one eutectic/bismuth based alloy annular packer. In this way the annular packer could be activated at a later stage if a leak were to develop.

(86) As noted above, it is envisaged that the technical benefits provided by the collar feature can also be achieved in downhole tool deployment assemblies that do not have a mandrel or outer tubular member (i.e. a tubular heat conduction member). The second aspect of the present invention relates to an assembly with a two-part heater body system, wherein part of the heater is configured to be retrievable once the alloy has been melted.

(87) The operation of the downhole tool deployment assembly of the second aspect of the present invention will now be described with reference to FIG. 4, which shows the key stages of the downhole tool deployment method.

(88) As with FIG. 3, the method will be demonstrated with reference to an OHGP. Once again, an open hole 100 is formed in an underground formation so as to access an underground oil/gas reservoir.

(89) The oil/gas is extracted from the reservoir via the production tubing 101, which in the region of the reservoir comprises a screen with a plurality of slots or apertures designed to allow the free flow of downhole fluids, including oil, into the tubing and ultimately out of the well.

(90) In order to prevent the slots or apertures of the tubing 101 becoming blocked, a proppant 102 is provided between the tubing 101 and the surrounding formation 100.

(91) In the first stage the assembly 200 is deployed downhole via the tubing 101 using delivery means 206. The assembly 200 comprises an up-hole tubular section 201 and a downhole tubular section 202. Both sections align to create a central cavity within which a heat source (e.g. chemical heat source) is received. The heat source has been omitted from FIG. 4 purely for the sake of clarity.

(92) The up-hole section 201 of the assembly is so described because in use it is located closest to ground level. Similarly, the downhole section 202 of the assembly is so described because in use it is located further down hole than the up-hole section.

(93) A point of weakness 204 is located at the point where the up-hole and downhole tubular sections of the assembly meet. Although not shown in any detail, it will be appreciated that the point of weakness may take the form of a weakened region of a single tubular body which is configure to break under a predetermined force to realise the up-hole and downhole sections of the assembly.

(94) Alternatively, the point of weakness may comprise fixing means that hold the up-hole and downhole sections together. These fixing means, which may be in the form of a sheer pin, a shear ring or a destructible screw thread, are configures to fail when a predetermined force is applied to the assembly 200.

(95) The point of weakness 204 is shielded by a collar 203, which is shown extending away from the lower end of the up-hole section 201 of the assembly. It is appreciated that in an alternative embodiment the collar may extend from the top end of the downhole section 202 in addition to or instead of the collar on the up-hole section.

(96) As described above with regard to the operation of the assembly of the first aspect of the present invention, the collar 203 serves to prevent molten alloy from cooling and re-solidifying over the separation point between the different sections of the assembly, which in the case of the assembly shown in FIG. 4 are the up-hole 201 and downhole sections 202.

(97) An alloy coating 205 is provided on the outside of the assembly so as to cover the collar 203 and at least part of both the up-hole 201 and downhole 202 sections thereof. The alloy 205 is a eutectic alloy, which may be bismuth based. The alloy coating 205 serves to reinforce the connection between the up-hole and downhole sections of the assembly so that the assembly retains a monolithic structure until the alloy is melted.

(98) As outlined above, in the first stage of the deployment process the assembly 200 is delivered downhole to a target region within the well. Once in position, the heat source is activated and the alloy 205 is melted.

(99) As the alloy 205 melts it flows down the body of the assembly away from the up-hole section 201 and thereby reveals the up-hole section. As the alloy flows, the collar 203 serves to direct the alloy 205 away from the point of weakness and thereby prevent molten alloy flowing into direct contact with the region at which the two sections of the assembly would be separated from one another.

(100) As the alloy 205 flows it starts to cool and re-solidify into a plug 205a. As can be seen from the second step shown in FIG. 4, the alloy can flow through the perforations into the surrounding annulus, thereby forming an alloy seal that extends across the entire cross-section of the wellbore 100.

(101) Once the alloy plug 205a has been allowed to cool and set, the delivery means 206 can be operated in reverse to pull the assembly out of the well. The pulling force of the delivery means works again the anchoring force of the plug 205a to impart a force separating force that exceeds the predetermined force required to break point of weakness so that the two sections of the assembly can be separated from one another.

(102) It will be appreciated that without the additional structural support of the alloy covering the point of weakness readily fails, thereby permitting the retrieval of the up-hole section of the assembly.

(103) In the final stage shown in FIG. 4 the plug 205a is shown in situ within the well. It should be noted that the length of the downhole section has been exaggerated for the purposes of clearly demonstrating the operation of the assembly. The actual length may be considerably less so as to ensure that, if necessary, the plug can be drilled/milled out relatively quickly.