PERFORATING TORCH APPARATUS AND METHOD
20220412194 · 2022-12-29
Assignee
Inventors
Cpc classification
E21B43/114
FIXED CONSTRUCTIONS
E21B43/119
FIXED CONSTRUCTIONS
International classification
Abstract
A tubular perforating apparatus includes a nozzle section comprising a nozzle head located therein and adjacent a combustible fuel material. The nozzle head includes an internal cavity and a nozzle portion including an opening on one side of the nozzle portion that directs the cutting fluids out the internal cavity in a first radial direction to produce a reaction force on the apparatus in an opposite second radial direction. The reaction force moves the apparatus in the second radial direction to be against an inner wall of the tubular and temporarily anchors the apparatus against the inner wall. The nozzle head is movable via the pressure and the cutting fluids from a closed position within the nozzle section to an open position in which the nozzle portion protrudes out of the nozzle section so that the opening is exposed to the tubular for directing the cutting fluids onto the tubular.
Claims
1. An apparatus for perforating a downhole tubular, the apparatus comprising: a fuel section having combustible material capable of producing cutting fluids; an igniter section coupled to the fuel section and having an igniter that ignites the combustible material so as to produce cutting fluids and pressure; and a nozzle section being in communication with the fuel section and comprising a nozzle head located therein and adjacent the combustible material, wherein the nozzle head comprises an internal cavity and a nozzle portion including at least one opening on one side of the nozzle portion that directs the cutting fluids out of the internal cavity in a first radial direction to produce a reaction force on the apparatus in a second radial direction that is opposite to the first radial direction, the reaction force moving the apparatus in the second radial direction to be against an inner wall of the downhole tubular and temporarily anchoring the apparatus against the inner wall, and the nozzle head is movable via the pressure and the cutting fluids from a closed position within the nozzle section to an open position in which the nozzle portion protrudes out of the nozzle section so that the at least one opening is exposed to the downhole tubular for directing the cutting fluids onto the downhole tubular.
2. The apparatus of claim 1, wherein there are at least two openings in the nozzle portion, the at least two openings being spaced circumferentially relative to each other, the at least two openings directing cutting fluids along parallel trajectories.
3. The apparatus of claim 1, wherein the nozzle section comprises an internal no-go shoulder, and the nozzle head comprises an outer shoulder that is configured to contact the internal no-go shoulder after the igniter ignites the combustible material to move the nozzle head relative to the nozzle section.
4. The apparatus of claim 1, wherein the nozzle head comprises at least one seal around a perimeter of the nozzle head.
5. A method of perforating a tubular having a closure, the method comprising: positioning a perforator in the tubular within a distance to the closure, the perforator comprising a movable nozzle head located within a nozzle section, the movable nozzle head comprising an internal cavity and at least one opening on one side of the movable nozzle head; operating the perforator to produce pressure and cutting fluids in the internal cavity to move at least a portion of the movable nozzle head out of the nozzle section so that the at least one opening is exposed to the tubular, and directing the cutting fluids in a first radial direction toward the tubular, wherein the production of cutting fluids produces a reaction force and a pressure wave in the tubular that is reflected off of the closure and back to the perforator; moving the perforator via the reaction force to be against the tubular; temporarily anchoring the perforator against the tubular while the reflected pressure wave impinges on the perforator; continuing to produce cutting fluids in the first radial direction, while the perforator is anchored against the tubular by the reaction force, to create an opening in the tubular; positioning a radial cutter in the tubular within the distance to the closure, with the opening located between the radial cutter and the closure; and operating the radial cutter to radially cut the tubular.
6. The method of claim 5, wherein the reaction force is a predetermined reaction force having a magnitude that is based on the distance of the perforator from the closure.
7. The method of claim 5, wherein the reaction force is a predetermined reaction force having a magnitude that is based on a clearance between the perforator and the tubular.
8. The method of claim 5, wherein the tubular has a drilling fluid with a density, and the reaction force is a predetermined reaction force having a magnitude that is based on the density of the drilling fluid.
9. The method of claim 5, wherein the tubular has a wall thickness, and the opening has a size, and the reaction force is a predetermined reaction force having a magnitude that is based on the tubular wall thickness and the size of the opening.
10. The method of claim 5, wherein the nozzle section comprises an internal no-go shoulder, and the nozzle head comprises an outer shoulder, and the outer shoulder contacts the internal no-go shoulder after the nozzle head is moved a predetermined distance relative to the nozzle section to prevent the nozzle head from completely exiting the nozzle section.
11. The method of claim 5, wherein the nozzle head is a first nozzle head, and the method further comprises replacing the first nozzle head with a second nozzle head after creating the opening.
12. The method of claim 11, wherein the second nozzle head includes a different opening than the at least one opening of the first nozzle head.
13. An apparatus for cutting a downhole tubular, comprising: a perforating tool comprising: a perforating igniter section; a perforating fuel section; and a perforating nozzle section, wherein the perforating fuel section contains combustible material capable of producing pressure and cutting fluids, the perforating igniter section contains an igniter that ignites the combustible material so as to produce cutting fluids, the perforating nozzle section is in communication with the perforating fuel section and comprises a nozzle head including an internal cavity and a nozzle portion that includes an opening on one side of the nozzle portion that directs the cutting fluids out of the internal cavity in a first radial direction to produce a reaction force on the perforating tool in a second radial direction that is opposite to the first radial direction, the reaction force moving the perforating tool in the second radial direction to be against an inner wall of the downhole tubular and temporarily anchoring the perforating tool against the inner wall, and the nozzle head is movable via the pressure and the cutting fluids from a closed position within the nozzle section to an open position in which the nozzle portion protrudes out of the nozzle section so that the opening is exposed to the downhole tubular for directing the cutting fluids onto the downhole tubular; and a cutting torch comprising: a cutting igniter section; a cutting fuel section; and a cutting nozzle section, wherein the cutting fuel section contains combustible material capable of producing cutting fluids, wherein the cutting igniter section comprises a second igniter that ignites the combustible material in the cutter fuel section, and wherein the cutting nozzle section is in communication with the cutting fuel section for discharging the cutter cutting fluids radially outward.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0016]
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DETAILED DESCRIPTION
[0028] 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.
[0029] 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.
[0030] Moreover, it will be understood that various directions such as “upper”, “lower”, “bottom”, “top”, “left”, “right”, “uphole”, “downhole”, 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.
[0031]
[0032] The present disclosure implements a perforating tool before a cutting torch is used. The perforating tool cuts an opening in the tubular or tubing 15 at a location above the closure 17. Once the tubular is opened, the cutting torch is then used to cut the tubular. The pressure wave created by the cutting torch is vented through the opening. Any reflection of the pressure wave back toward the torch is attenuated so that the torch does not move. This results in a successful cutting of the tubing 15. The perforating tool also creates a pressure wave when it creates the opening. This pressure wave is reflected off of the closure back to the tool. However, the perforating tool uses the reaction force of the cutting fluids it generates to anchor the tool against the tubing and remain stationary even in the face of encountering the reflected pressure wave. In the following description, the perforating tool will be described first, followed by a description of the cutting torch. A description of the operation of the perforating tool and cutting torch will then be provided.
[0033]
[0034] The ignition section 35 contains an ignition source 41. In the preferred embodiment, the ignition source 41 is a thermal generator. The thermal generator 41 may be a self-contained unit that can be inserted into the extension member. The thermal generator 41 has a body 43, flammable material 45 and a resistor 47. The ends of the tubular body 43 are closed with an upper end plug 49, and a lower end plug 51. The flammable material is located in the body between the end plugs. The upper end plug 49 has an electrical plug 53 or contact that connects to an electrical cable (not shown). The upper plug 49 is electrically insulated from the body 43. A resistor 47 is connected between the electrical plug 53 and the body 43. The flammable material 45 may be a non-explosive material, e.g., thermite, or modified thermite, mixture. The thermite mixture includes a metal and an oxidizer (e.g., a powdered or finely divided metal and a powdered metal oxide or other oxidizer). The metal can include aluminum, magnesium, etc. The metal oxide can include cupric oxide, iron oxide, aluminum oxide, etc. In an embodiment, the thermite mixture is cupric oxide and aluminum. When ignited, the flammable material produces an exothermic reaction. The flammable material has a high ignition point and is thermally conductive. The ignition point of cupric oxide and aluminum is about 1200 degrees Fahrenheit. Thus, to ignite the flammable material, the temperature must be brought up to at least the ignition point and preferably higher. In an embodiment, the ignition point of the thermite mixture is as low as 900 degrees Fahrenheit.
[0035] The fuel section 39 contains the fuel. The fuel may in some embodiments be combustible material in the form of a solid, a liquid, or a gel. The combustible material may be non-explosive fuels such as thermites, modified thermites (containing gasification agents) or thermite mixtures containing binders, low explosives such as propellants and pyrotechnic compositions or modified liquid or gelled fuels with metal and/or metal oxide additives. In some embodiments, the non-explosive combustible fuels may be in the form of single or multiple stacked combustible pellets 55, e.g., thermite pellets. The pelletized fuel may be installed within the assembly prior to shipping. In other embodiments, the pelletized fuel may be installed in the assembly at the work site so that the mass of fuel can be adjusted to suit the specific well conditions, constraints, and operational requirements such as hydrostatic pressure or changes to the cutting requirements. In the preferred embodiment, the fuel can be made up of a stack of pellets 55 which are donut or toroidal shaped. When stacked, the holes in the center of the pellets 55 are aligned together. The holes can be filled with loose combustible fuel material 57, which may be of the same material as the pellets 55. When the combustible fuel material combusts, it generates pressure and hot combustion fluids that are sufficient to cut through a tubular wall, if properly directed. The combustion fluids comprise gasses and liquids. In the embodiment shown in
[0036] The pellets 55 can be adjacent to, and abut, a nozzle head 38 that is provided in the nozzle section 37. The nozzle head 38 can comprise an internal cavity 61 that can be lined with a heat resistant liner 71, which may be formed of carbon in an embodiment. The liner 71 protects the nozzle head 38 from the cutting fluids generated by the fuel section. The liner 71 can be perforated at a nozzle opening 62, and the liner 71 can comprise a cylindrical side wall and a bottom wall. The nozzle opening 62 can be formed through the nozzle head 38 for providing passage from the internal cavity 61 to outside of the nozzle head 38, and can allow communication between the interior and exterior of the nozzle section 37. The nozzle opening 62 opens in a plane perpendicular to a central axis of the perforating tool 31, as shown in
[0037] When the fuel pellets 55 are ignited, the pressure of combustion fluids generated by the ignited fuel enters the internal cavity 61 of the nozzle head 38 and forces the nozzle head 38 downward from a first position within the nozzle section 37, as shown in
[0038] The nozzle head 38 in the embodiment shown in
[0039] In the embodiment shown in
[0040]
[0041] The operation and use of the perforating torch 31 and radial cutting torch 19 will now be described, using the example of plugged coiled tubing (tubular or tubing) 15. Referring to
[0042] Because the nozzle opening 62 is located on one side of the nozzle head 38, the combustion fluids 21 are directed in a first direction to that one side. The expulsion of combustion fluids 21 on the one side creates a reverse action, or reaction, force 101 which causes the perforating tool 31 to move in a second direction opposite to the first direction, as shown in
[0043] In one embodiment, the perforating tool 31 is then removed and replaced with the radial cutting torch 19, as shown in
[0044] The amount of reaction force needed on the perforating tool 31 may depend on the strength of the pressure wave 23 that impacts the perforating tool 31. The strength of the pressure wave 23 may be dependent upon several factors, such as the amount and type of fuel used. Another factor is the distance of the perforating tool 31 from the closure 17 and the clearance between the perforating tool 31 and the tubing 15. The closer the perforating tool 31 is placed to the closure 17, the stronger the pressure wave 23 that impacts the perforating tool 31 and the more likely the impact of the pressure wave 23 is to coincide at the same time that the combustion fluids 21 are cutting the tubular. The smaller the clearance between the outside diameter of the perforating tool 31 and the inside diameter of the tubing 15, the stronger the pressure wave 23, as the bulk of pressure wave 23 is encountered by the perforating tool 31 and not bypassed through the clearance. The density and makeup of the drilling fluids inside of the tubing 15 may also have a bearing on the pressure wave 23, as some drilling fluids are more efficient in propagating pressure waves. Additionally, the more energy required to form the tubular opening 103, the larger the pressure wave 23 is likely to be created, requiring a greater reaction force. A larger opening 103 and thicker tubular wall requires more energy from the combustion fluids to form the tubular opening 103. Thus, an opening 103 that requires a large amount of energy will likely have a larger pressure wave 23. The larger pressure wave 23 can be compensated for with a larger reaction force. A larger reaction force can be created by narrowing the arc A (see
[0045] In one embodiment, after the perforating tool 31 is removed from the tubing 15, the nozzle section 37, including the nozzle head 38, may be detached from the perforating tool 31 and replaced with another nozzle section 37 having another nozzle head. That is, the nozzle section 37 may be detachably attached, e.g., by a threaded connection, to the fuel section 39, so that the nozzle section 37 may be easily detached from the fuel section 39. The other nozzle head may be different than the original nozzle head 38 by having a different arrangement or pattern of nozzle opening(s) 62. This process may be conducted at the well site or other locations. In other embodiments, the nozzle section 37 may be detachably attached from the fuel section 39 in order to replace or modify the fuel load, i.e., the pellets 55 and/or the combustible fuel material 57. Replacing the nozzle section 37 so that the perforating tool 31 has a different nozzle head may be advantageous if the different nozzle head is more suited to a particular perforating operation. Similarly, detaching the nozzle section 37 to replace or modify the fuel load may be advantageous if the different fuel load is more suited to a particular perforating operation. For instance, more pellets 55 may be added, or some of the existing pellets 55 may be removed. Alternatively, at least some of the pellets 55 may be removed and replaced with different pellets having a different composition than the existing pellets 55. The detachable nozzle section 37 provides the perforating tool 31 with a modularity that is beneficial when the perforating tool 31 is already in the field, making the perforating tool 31 adaptable to different perforating operations while in the field. For instance, the perforating tool 31 may be part of a kit that includes a variety of nozzle sections 37 having different nozzle heads 38 that are attachable to the fuel section 39 via, e.g., a threaded connection. The kit may also include a variety of different pellets that may replace existing pellets, or that may otherwise be added or inserted into the fuel section 39.
[0046]
[0047] The perforating tool 31 has been described herein in conjunction with a cutting torch 19. However, the perforating tool 31 can be used without a cutting torch 19. For example, if a drill pipe or other tubular becomes stuck in a borehole, it may be desirable to create one or more large holes in the drill pipe to allow circulation. The perforating tool 31 may be used to create one or more large openings in the drill pipe. The perforating tool can be used close to and above the check valve or other closure 17 in the drill pipe. In this operation, the opening pattern in the nozzle head can be a relatively large circular opening or openings. The diameter of the opening(s) may be such that a backward reaction force is created to pin the perforating tool 31 against the drill pipe. The radial cutting torch 19 is not used in this scenario.
[0048] Furthermore, the perforating tool 31 can be used for correcting cement jobs. Typically, cement is pumped down inside casing to the bottom and then back up around the outside of the casing. On occasion, the cement around the outside of the casing has voids. The perforating tool 31 can be used to create an opening in the casing at the void. Once the opening is created, cement can be pumped down the inside of the casing, out through the opening and into the void. The perforating tool 31 can generate large openings which allow the cement to be pumped through at high volumes and high flow rates. In another instance, the perforating tool 31 can be used to create openings in tubular such as casing for introducing loss circulation materials into the borehole.
[0049] 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.