Device and method to stimulate a geologic formation with electrically controllable liquid propellant-waterless fracturing

Abstract

This application describes a device for stimulating a geologic formation using an electrically throttled liquid propellant. The device may be used for primary stimulation, changing the direction of a fracture in a wellbore during hydraulic fracturing, a re-frac of an existing interval to open new areas in an open interval, or reset fracture conductivity after extended shut in of the well. This comprises deploying the device on tubing or wireline and positioning it close to the selected wellbore interval where liquid propellant can be selectively ignited. The device's controls release and ignite an energetic material that produces expanding gas to increase pressure and stimulate the selected interval. The device is comprised of a reservoir to hold energetic material, a metering system to release propellant at a desired rate, an electrical ignition source to control output, a no backflow valve, and control module that operates the metering and electrical ignition.

Claims

1. An apparatus for selectively stimulating an interval in a production casing by controlling the rate of gas produced by an ignited propellant comprising: coiled tubing with a coaxial power and communication cable therein; a meter valve for regulating the flow in the tubing of a liquid propellant at least one electronic trigger for igniting the liquid propellant; a control module for controlling the meter valve and the electronic trigger; a position locating and anchor device for locating a known position within the production casing and anchoring at the position; at least one backflow valve for controlling the direction of flow of the liquid propellant and a nozzle for dispersing at least one or more of the liquid propellant or a gas generated by the ignition of the liquid propellant.

2. The apparatus of claim 1 wherein the liquid propellant is an electrically triggerable liquid propellant.

3. The apparatus of claim 1 wherein the production casing comprises a known marker.

4. The apparatus of claim 3 wherein the position locating and anchor device comprises expanding keys for anchoring into the production casing.

5. The apparatus of claim 1 wherein the nozzle is designed to pull tension on the tubing when at least one or more of the liquid propellant, or a gas generated by the ignition of the liquid propellant, exits the nozzle.

6. The apparatus of claim 1 wherein the control module regulates the flow of the liquid propellant.

7. The apparatus of claim 1 where the control module regulates power to the electronic trigger to throttle the gas created by ignition of the liquid propellant.

8. The apparatus of claim 1 wherein the electronic trigger ignites the liquid propellant that is inside the coiled tubing.

9. The apparatus of claim 1 wherein the electronic trigger ignites the liquid propellant that is outside of the coiled tubing.

10. The apparatus of claim 1 wherein the electronic trigger is positioned on the outside of the production casing.

11. The apparatus of claim 1 further comprising at least one electrically controlled packer located on the coiled tubing above the control module and at least one electrically controlled packer below the nozzle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 depicts a common horizontal well with locating marker with profile positioned across desired production intervals

(2) FIGS. 2A-C show three common device configurations. FIG. 2A depicts a base stimulation tool embodiment; FIG. 2B depicts a stimulation tool embodiment for use in a waterless fracturing application; and FIG. 2C depicts a stimulation tool embodiment for use in re-fracturing.

(3) FIG. 3 depicts an expanded view of a stimulation tool configuration from FIG. 2A inside an expanded view of a sleeve with locating marker with profile.

(4) FIG. 4 depicts a logic diagram for the control module

(5) FIG. 5 depicts a detailed diagram for the control module

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

(6) FIG. 1 shows an illustration of a horizontal wellbore with a plurality of locating markers with profile (14). These markers may be sliding sleeves with open and closed position, propellant tool as described in patent U.S. Pat. No. 9,896,920, or cluster of shaped charge perforations that are part of the production casing (3). The stimulation assembly (2A,2B,2C) is capable of identifying the locating markers with profile (14) and anchoring the device in the proper position. A production packer (27) anchors the production casing (3) and is placed just above the horizontal section of the production casing (3) to isolate the productive pay zone from the intermediate casing. A float shoe (28) is run on the end of the casing to prevent backflow of cement after cementing the production casing (3) in place. The Illustration shows five locating markers with profile (14). It is common practice to have 50 or more of these in a single wellbore. The length between the intervals may vary based on completion preferences.

(7) FIG. 2A is a base stimulation tool. The device would provide additional flow rate inside the production casing during a casing frac. It could also be used to stimulate new or existing intervals in the production casing (3). This is the base device used in FIG. 3. FIG. 2B has a packer (26) on the lower end of the stimulation tool (2B). The packer on the lower will direct all flow inside the production casing (3) above the packer (26). The stimulation tool (2B) would be used in a waterless fracturing application that started at the toe end of the production casing, in conjunction with an on/off sleeve or a propellant stimulation tool, and work additional intervals toward the heel end of the production casing.

(8) FIG. 2C has two packers (26) that isolate the section between the stimulation tool (2C). This stimulation tool (2C) would be used for re-fracturing an open interval in the production casing (3). The packers (26) isolate the area between them and assure the flow is directed into the desired interval in the production casing. It operates the same as the explanation in FIG. 3. All three examples use a reservoir of liquid propellant (7), a metering device (11), and a least one electric trigger (12). This is the basic components required to provide a propellant reaction that can be controlled in a beneficial manner. The pressure in the reservoir must be higher than the pressure in the production casing to force the liquid propellant through the metering device (11) and past the electric trigger (12). Additions such as the control module (8) and peripherals on control module extension (23) provide greater control and flexibility thus maximizing the value of the invention.

(9) FIG. 3 is a view of the process associated with use of a base stimulation tool inside a production casing (3). An external pump (1) provides positive pressure inside the coiled tubing that will force the liquid propellant in the annular area between the coiled tubing and the inside diameter of the production casing (3) when the metering device (11) is open. The external pump (1) will have a motor and fluid source and can be controlled manually or electronically using a surface control unit. The coiled tubing unit (2) is a mobile unit that carries enough coiled tubing to get to the deepest depth in the production casing (3) along with all the items required to attach to the wellhead. It is responsible for moving the coiled tubing (4) in and out of the production casing (3) to position the stimulation tool (2A) in the correct location. The coiled tubing (4) will contain a coaxial single or multi-conductor wire (5) on the inside of the coiled tubing that will provided power and communication from the surface control unit, that is part of the coiled tubing unit (2), to the control module (8) that is part of the stimulation tool (2A).

(10) The coiled tubing (4) will contain a predetermined amount of propellant (7) inside the coiled tubing (4). The propellant (7) will start at the control module (8) and extend up the coiled tubing (4) to a wiper ring (6). The wiper ring (6) is a seal that provides isolation from the fluid used to pressure the inside diameter of the coiled tubing (4) and the liquid propellant (7). Once the stimulation tool (2A) is attached to the coiled tubing (4) the components power is applied to the coaxial cable (5). The control module will perform a series of programmed checks and verify the stimulation tool (2A) is ready to deploy. Once the control module (8) receives conformation the system passed the tests the stimulation tool (2A) is ready to be moved to the first stimulation position in production casing (3). The control module (8) is programmed to locate a specific position in the production casing (3). Once identified the control module will send power to the position locating and anchor device (9) that will expand keys that locate and anchor in the locating marker with profile (14).

(11) Once anchored, the stimulation tool is ready to stimulate. The internal pressure is increased inside the coiled tubing (4) with the external pump (1), the meter valve (11) is opened to the desired flow area, and the electric trigger (12) is activated with the designated power to ignite the liquid propellant (7). The gas flows out of the nozzle (13) and into the interval to be stimulated through the locating marker with profile (14). The control module (8) regulates the volume of liquid propellant and the power to the electric trigger (12). There are two ways to regulate gas production. One is with the volume of liquid propellant released to flow across the electric trigger. The second is the power to electrodes inside the electric trigger (12). The more electrodes that are energized, the more propellant is activated prior to exiting the nozzle (13). It is possible for some of the liquid propellant not to ignite until after it is past the nozzle (13). Control of the meter valve (11) and electric trigger (12) may be done from surface control unit or logic programmed in the control module (8). The movement of liquid propellant (7) is based on higher pressure inside the coiled tubing (4) than inside production casing (3). It is important the propellant does not flow back into the coiled tubing (4) during stimulation. This could ignite propellant in the reservoir of liquid propellant (7).

(12) A backflow prevention valve (10) is positioned between the position locating and anchor device (9) and the metering device (11). If the control module (8) detects backflow it will close the meter valve (11) and turn off the electric trigger (12) until a positive differential pressure is recognized inside the coiled tubing (4). The control module (8) uses information from peripherals such as pressure gauges and temperature gauges (24,25), and a flow meter (22) to analyze operation. It may be common for the electric trigger (12) and metering valve (11) to move between on and off position many times during stimulation. Once stimulation is complete the control module (8) closes the meter valve (11), turns power off to the electric trigger (12), and signals the position locating and anchor device (9) to release the keys. The program loads the next location into the control module (8) and begins reading to find the next interval. The nozzle (13) is a ported device that may contain up to three rows of ports. One row will angle up, one row will be 90 degrees to the ID, and one row will be angle down. The flow area will be set such that the upper row will discharge more gas and result in some tension on the stimulation device near the maximum designed flow rates.

(13) The back flow (10) valve may be of several designs. A ball and seat would provide secure shut off while a tesla valve would provide resistance to back flow. The device may contain more than one backflow valve and any combination of valves. The metering device (11) will have a fully open, variable orifice, and fully closed position that is electrically controlled. The fail-safe position is closed. It may be a needle and seat controlled by a stepper motor or a variable meter like Fluid Metering Inc.'s valve less technology.

(14) The control module (8) will contain a custom electronics board (20) with a processor connected to desired peripherals connected to the control module extension (23). The electronics card (20) will contain firmware capable of making decisions that adjust the peripherals function during operation. Electronics card (20) will contain a memory module to log events during stimulation of an interval. The location and anchoring device (9) will have a device such as coils capable of reading markers permanently located in the production casing (3) or some other locating method such as a collar locator, with communication to the control module (8). It will contain an anchoring method such as keys or slips with teeth that grip the production casing (3) that may be activated with an electric motor or electromagnetic force.

(15) FIG. 4 contains a basic logic sequence for the control module (8) and surface control unit. This logic is built into the firmware on the electronics card (20) contained in the control module (8). A surface control device such as a laptop PC or PLC controller would connect and communicate with electronics card (20).

(16) FIG. 5 is a detailed view of the control module (8) with the some of the optional peripherals on control module extension (23). The firmware on the electronics card (20) in control module (8) can make decisions based on information from the peripherals and change the settings on the metering device (11) and/or the electric trigger (12) with or without assistance from surface depending on configuration. The tension and compression load with accelerometer (18) provide information regarding the loading on the coiled tubing (4) at the control module (8). It provides a clear indication that the position locating and anchor device (9) is properly anchored. Information on the loading and movement during the stimulation as well as proper release of the locating and anchoring device (9) are recorded and sent to surface in real time.

(17) The coaxial line (5) from surface terminates at the control module (8). This is the path for raw power and two-way communication. The power and communication regulator (19) conditions the power and sends the proper voltage to the electronics card (20). It also receives information from the electronics card (20) and sends it back to surface. The electronics card (20) contains all the electronic components required to send and receive communication to surface, store information from peripherals, motor or other controls to function peripherals, and firmware and software to process information received from surface and the peripherals. The power and communication wire (21) provide a link for power and communication from the electronics card (20).

(18) The Flowmeter (22) is capable of reading flow rate inside control module peripheral extension (23) in either direction. It can also determine the direction of flow. The control module peripheral extension (23) provides the necessary accommodations for the peripherals. This part may vary with different peripheral configurations. The ID pressure and temperature recorder (24) provides information for the inside of the coiled tubing (4). It is particularly important the pressure inside the coiled tubing (4) is higher than the outside pressure. This prevents backflow and accidental ignition of the propellant in the reservoir. The Outside Diameter pressure and temperature recorder (25) records pressure and temperature between the outside of the control module (8) and the inside of the production casing (3). The lower end of control module peripheral extension (23) connects to the position locating and anchor device (9).

(19) TABLE-US-00001 Drawing Reference Description  1 External High pressure pump  2 Coiled Tubing unit  3 Production casing  4 Coiled Tubing  5 Coaxial electric line  6 Wiper spacer ring  7 Liquid propellant.  8 Control module  9 Position locating and anchor device 10 Backflow prevention valve 11 Metering device 12 Electronic trigger device 13 Nozzle 14 Locating marker with profile.  2A Base Stimulation Tool  2B Waterless Fracturing Stimulation Tool  2C Re-fracturing Stimulation Tool 18 Tension and compression load and accelerometer 19 Power and communication regulator 20 Electronics Card 21 Power and communication wire 22 Flow meter 23 Control module extension 24 ID pressure and temperature recorder 25 OD pressure and temperature recorder 26 Packer 27 Production Packer 28 Float Shoe