Apparatus and methods for overcoming an obstruction in a wellbore
10472913 ยท 2019-11-12
Assignee
Inventors
- Michael C. Robertson (Arlington, TX, US)
- William F. Boelte (New Iberia, LA, US)
- Douglas J. Streibich (Forth Worth, TX, US)
Cpc classification
International classification
Abstract
Apparatus and methods for penetrating a downhole target within a wellbore include providing a body with a longitudinal axis, a first end, and a second end into a wellbore, the body having a nozzle at the first end. The nozzle is adapted to project a medium in a direction generally parallel to the longitudinal axis to affect a downhole target. An actuator in communication with the medium is usable to initiate the apparatus. The nozzle can be provided with a geometry configured for projecting the medium in a pattern that separates the downhole target into at least two portions. The medium can include a ferromagnetic material that becomes associated with the downhole target to facilitate recovery of the target or portions thereof using a retrieval device having a magnetic element.
Claims
1. An apparatus for penetrating a downhole target within a wellbore having an axis, wherein the apparatus comprises: a body having a longitudinal axis, a first end, and a second end; a medium associated with the body; a nozzle at the first end of the body, wherein the nozzle projects the medium in a direction generally parallel to the longitudinal axis, and wherein the nozzle comprises a surface adapted to face the downhole target, and at least two elongated slots extending in a radial direction on the surface and oriented in a geometry configured for projecting the medium in a pattern adapted to separate the downhole target into at least two portions; and an actuator in communication with the medium, wherein actuation of the actuator causes projection of the medium through the nozzle in the pattern, in the direction generally parallel to the longitudinal axis of the body and generally parallel to the axis of the wellbore for affecting the downhole target.
2. The apparatus of claim 1, further comprising a stand-off member associated with the first end of the body, wherein the stand-off member has a dimension that provides a space between the nozzle and the downhole target.
3. The apparatus of claim 2, wherein the stand-off member is adapted to be at least partially eroded by the medium.
4. The apparatus of claim 1, further comprising a connector associated with the second end of the body, wherein the connector, a device attached to the connector, or combinations thereof, anchors the body in a generally fixed orientation relative to the wellbore to prevent movement of the body due to actuation of the actuator, projection of the medium, or combinations thereof.
5. The apparatus of claim 1, further comprising a cap associated with the first end of the body, wherein the cap is configured to seal the nozzle to prevent entry of contaminants.
6. The apparatus of claim 5, wherein the cap is adapted to be at least partially eroded by the medium.
7. The apparatus of claim 1, wherein the orientation of the at least two elongated slots is such that projection of a blade, the medium or combinations thereof, separates the downhole target into a plurality of wedge-shaped portions.
8. The apparatus of claim 1, wherein the medium comprises an explosive charge, a corrosive medium, a molten medium, or combinations thereof.
9. The apparatus of claim 1, wherein the medium comprises ferromagnetic material, and wherein projection of the medium adheres, coats, fuses, bonds, or combinations thereof, the ferromagnetic material to the downhole target, thereby enabling magnetic retrieval of the at least two portions thereof.
10. The apparatus of claim 9, wherein the medium comprises thermite.
11. The apparatus of claim 10, wherein projection of the thermite forms a ferromagnetic matrix on the downhole target.
12. A method for at least partially removing an obstruction from a wellbore having an axis, the method comprising the steps of: positioning a body in the wellbore at a distance from the obstruction, wherein the body comprises a nozzle comprising a surface adapted to face the obstruction, and at least two elongated slots extending in a radial direction on the surface and oriented in a geometry for projecting a medium in a direction generally parallel to the axis of the wellbore, wherein the geometry is configured for projecting the medium in a pattern adapted to separate the obstruction into at least two portions; and projecting the medium through the nozzle in the direction generally parallel to the axis of the wellbore, wherein the medium elects at least one portion of the obstruction, thereby at least partially removing the obstruction from the wellbore.
13. The method of claim 12, wherein the step of positioning the body at the distance from the obstruction comprises providing the body with a stand-off member having a dimension that provides a space between the nozzle and the obstruction.
14. The method of claim 13, further comprising a step of consuming a fuel load to cause projection of the medium through the nozzle, which causes the medium to at least partially erode the stand-off member.
15. The method of claim 12, further comprising the step of providing a cap into association with the body, wherein the cap is configured to seal the nozzle to prevent entry of contaminants, and wherein projecting the medium through the nozzle at least partially erodes the cap.
16. The method of claim 12, further comprising the step of anchoring the body in a generally fixed orientation relative to the wellbore to prevent a movement of the body due to projection of the medium.
17. The method of claim 16, wherein the step of anchoring the body comprises providing a counterforce apparatus associated with the body, wherein the step of projecting the medium through the nozzle applies a force to the body, and wherein the counterforce apparatus produces a counterforce that opposes the force such that the body remains in the generally fixed orientation relative to the wellbore.
18. The method of claim 17, further comprising the step of providing the counterforce apparatus with an output, a duration, or combinations thereof, that corresponds to the geometry of the nozzle, the force, or combinations thereof.
19. The method of claim 12, wherein the step of projecting the medium separates the obstruction into a plurality of wedge-shaped portions.
20. The method of claim 12, wherein the medium comprises ferromagnetic material, wherein the step of projecting the medium comprises associating the ferromagnetic material with the obstruction, and wherein the method further comprising the step of magnetically retrieving said at least two portions of the obstruction.
21. A method for removing and retrieving a downhole object from a wellbore, wherein the method comprises the steps of: positioning a body in the wellbore at a distance from the downhole object, wherein the body comprises a nozzle to project a medium comprising a ferromagnetic material, the nozzle comprising a surface adapted to face the downhole object, and at least two elongated slots extending in a radial direction on the surface; contacting the downhole object with the medium comprising the ferromagnetic material, thereby associating the downhole object with the ferromagnetic material; and contacting the ferromagnetic material with a retrieval device comprising a magnetic element, thereby associating the downhole object with the retrieval device.
22. The method of claim 21, wherein the medium comprises thermite, and wherein the step of contacting the downhole object with the medium comprises projecting molten thermite into contact with the downhole object, thereby at least partially fusing the ferromagnetic material to the downhole object.
23. The method of claim 21, further comprising the steps of: projecting the medium through the nozzle in the direction generally parallel to the axis of the wellbore.
24. The method of claim 23, wherein the nozzle comprises a geometry for projecting the medium in a pattern adapted to separate the downhole target into at least two portions associated with the ferromagnetic material.
25. The method of claim 24, wherein the step of projecting the medium separates the downhole object into a plurality of wedge-shaped portions associated with the ferromagnetic material.
26. The method of claim 21, wherein the step of contacting the downhole object with the medium separates the downhole object into at least two portions associated with the ferromagnetic material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the detailed description of various embodiments usable within the scope of the present disclosure, presented below, reference is made to the accompanying drawings, in which:
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(14) One or more embodiments are described below with reference to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
(15) Before describing selected embodiments of the present disclosure in detail, it is to be understood that the present invention is not limited to the particular embodiments described herein. The disclosure and description herein is illustrative and explanatory of one or more presently preferred embodiments and variations thereof, and it will be appreciated by those skilled in the art that various changes in the design, organization, means of operation, structures and location, methodology, and use of mechanical equivalents may be made without departing from the spirit of the invention.
(16) As well, it should be understood that the drawings are intended to illustrate and plainly disclose presently preferred embodiments to one of skill in the art, but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views to facilitate understanding or explanation. As well, the relative size and arrangement of the components may differ from that shown and still operate within the spirit of the invention.
(17) Moreover, it will be understood that various directions such as upper, lower, bottom, top, left, right, and so forth are made only with respect to explanation in conjunction with the drawings, and that components may be oriented differently, for instance, during transportation and manufacturing as well as operation. Because many varying and different embodiments may be made within the scope of the concept(s) herein taught, and because many modifications may be made in the embodiments described herein, it is to be understood that the details herein are to be interpreted as illustrative and non-limiting.
(18) Referring now to
(19) Specifically, the depicted apparatus (10) is shown having an elongate, tubular body (12) having a box end (14) and a pin end (16). The pin end (16) is depicted having sealing elements (18) (e.g., O-rings or similar elastomeric and/or sealing members) associated therewith. A fuel load (20) is shown disposed within and substantially filling the central bore of the body (12). In an embodiment, the fuel load (20) can include thermite and/or a mixture of thermite and one or more polymers adapted to produce a gas and/or force as the thermite combusts, such as the power source described in U.S. Pat. Nos. 8,196,515 and 8,474,381, which are incorporated herein by reference in their entireties.
(20) In operation, the box end (14) and/or the pin end (16) of the depicted apparatus (10) can be configured to function as a nozzle, such that when the fuel load (20) is consumed (e.g., through actuation of a thermal generator or other type of ignition source or actuator), a medium (e.g., molten thermite) is projected through the nozzle, generally parallel to the axis of the body (12). The medium can subsequently affect an obstruction within a wellbore (e.g., a flapper valve, debris, a setting tool, a restriction, or other similar types of obstacles) located in an axial direction (e.g., uphole or downhole) relative to the apparatus (10), e.g., by at least partially degrading, perforating, penetrating, and/or eroding the obstruction.
(21) As described above, however, the depicted apparatus (10) can be used in conjunction with additional containers and/or apparatus containing additional fuel, or the depicted apparatus (10) can function as a carrier for a fuel load (20) for use by an associated apparatus. Similarly, an initiation apparatus can be threaded to and/or otherwise engaged with either end (14, 16) of the apparatus (10), and/or other attachments and/or components can be engaged with the depicted apparatus (10), such as a stand-off member, an anchor and/or attachment/latching mechanism, or other similar components, as described above and below.
(22) Referring now to
(23) The depicted embodiment of the apparatus (26) is shown having an insert (40) disposed within the body (28) proximate to the second end (32), which in an embodiment, can be formed from graphite or a similar material that will remain generally unaffected by the consumption of a fuel load and the projection of a medium. The insert (40) is shown having an internal bore, which is continuous with a bore through the stand-off member (36), defining a nozzle (42) at the second end (32) of the body (28). The stand-off member (26) is depicted having a seal and/or plug (44) engaged therewith, over the nozzle (42), with an associated O-ring or similar sealing member (46), such that the seal and/or plug (44) blocks the opening of the nozzle (42) while the apparatus (26) is lowered and/or otherwise positioned within the wellbore. The seal and/or plug (44) thereby prevent(s) the entry of contaminants into the nozzle (42) and body (28), until the apparatus (26) is actuated. Consumption of the fuel load (48), which in an embodiment, can include thermite and/or a thermite-polymer mixture, causes projection of a medium (e.g., molten thermite and/or gas) through the nozzle (42), which can remove and/or penetrate and/or otherwise degrade the seal and/or plug (44), and further affect an obstruction located external to the apparatus (26) (e.g., located in an axial direction proximate to the second end (32) thereof.)
(24) It should be understood that the nozzle (42), the fuel load (48), the stand-off member (36), and other components of the apparatus (26) can be readily varied and/or provided having other dimensions, shapes, and/or forms without departing from the scope of the present disclosure. For example,
(25) Referring now to
(26) It should be understood that various components of the depicted apparatus (58) can be readily modified without departing from the scope of the present disclosure. For example,
(27) Each of the embodiments shown in
(28) In use, any of the above-described embodiments, and/or another similar apparatus configured to project a medium in an axial direction can be positioned within a wellbore (e.g., by lowering the apparatus via a conduit engaged with the upper end/top connector thereof). The apparatus can be anchored in place, such as through use of a positioning and latching system, such as that described in U.S. Pat. No. 8,616,293, which is incorporated herein by reference in its entirety. For example, a latching member can be engaged to an embodiment of the present apparatus via a connection to the upper end/top connector thereof. In other embodiments, various other types of anchors, setting tools, and/or securing devices can be used to retain the apparatus in a generally fixed position within a wellbore without departing from the scope of the present disclosure.
(29) In a further embodiment, any of the above-described embodiments, and/or another similar apparatus can be positioned within a wellbore, facing a first direction (either uphole or downhole), while a second identical or similar apparatus can be provided, facing the opposite direction. The two apparatus can be actuated simultaneously, such that the force produced by the second apparatus (e.g., a counterforce apparatus), counteracts and/or otherwise opposes the force applied to the first apparatus by consumption of the fuel load and projection of the medium, thereby retaining both apparatus in a generally fixed position within the wellbore during use. The nozzle geometry, fuel load, and/or other characteristics of the second/counterforce apparatus can be selected based on the nozzle geometry, fuel load, and/or other expected forces associated with the first apparatus.
(30) As described above, depending on the nature of an obstruction in a wellbore, it may be desirable to use multiple apparatus in succession, each having a differing nozzle geometry. For example,
(31) A first apparatus (A1), such as an apparatus similar to that shown in
(32) Following use of the first apparatus (A1), a second apparatus (A2), such as an apparatus similar to that shown in
(33) Following use of the second apparatus (A2), a third apparatus (A3), such as an apparatus similar to that shown in
(34) Referring now to
(35) The apparatus (100) is shown having a generally tubular body (102) with a bore and/or cavity (104) therein, usable to contain a medium (e.g., a thermite-based fuel load or other types of media) for affecting a downhole target, such as a flapper valve. The body (102) includes a first end (104) having a nozzle (110) engaged therewith, and a second end (108) usable to engage the apparatus (100) to an adjacent component, connector, conduit, and/or other type of object.
(36) The nozzle (110) is shown having a geometry adapted to separate a flapper valve or similar downhole object and/or obstruction into portions (e.g., wedge-shaped pieces). Specifically, the depicted nozzle (110) includes four slots (112A, 112B, 112C, 112D) extending in a radial direction and spaced generally equally about the face of the nozzle (110). A diverter (114) is positioned adjacent to the nozzle (110), toward the interior of the body (102).
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(38) In use, a medium (e.g., molten thermite) can be projected from the interior of the body (102) toward the nozzle (110), guided by the diverter (114) through the slots (112A, 112B, 112C, 112D), such that the molten thermite or similar medium that exits the apparatus (110) is projected in a pattern corresponding the position of the slots (112A, 112B, 112C, 112D), thereby affecting a downhole target by separating and/or severing the downhole target into wedge-shaped pieces generally corresponding to the portions of the nozzle (110) unoccupied by slots. For example, during typical use, projection of molten thermite through the depicted nozzle (110) would sever a flapper valve into four wedge-shaped pieces by cutting generally perpendicular slots through the valve.
(39) For example,
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(41) Embodiments usable within the scope of the present disclosure thereby provide apparatus and methods usable to penetrate, perforate, and/or erode a target that presents a blockage, hindrance to travel, and/or inadequate flow path in a wellbore, through the projection of a medium to affect the obstruction. Embodiments can include use of nozzles having geometries adapted for separating a downhole target, such as a flapper valve, into multiple portions, and can further include methods for applying a ferromagnetic property to previously non-ferromagnetic objects to facilitate retrieval of the objects.
(42) While various embodiments usable within the scope of the present disclosure have been described with emphasis, it should be understood that within the scope of the appended claims, the present invention can be practiced other than as specifically described herein.