Hybrid stimulation tool and related methods
11661825 · 2023-05-30
Assignee
Inventors
- Bader Ghazi Al-Harbi (Dammam, SA)
- Sameeh Issa Batarseh (Dhahran, SA)
- Norah Abdullah Aljeaban (Khubar, SA)
Cpc classification
E21B43/114
FIXED CONSTRUCTIONS
E21B43/2405
FIXED CONSTRUCTIONS
E21B43/119
FIXED CONSTRUCTIONS
International classification
Abstract
This application relates to systems and methods for stimulating hydrocarbon bearing rock formations using a downhole hybrid tool for discharging a fracturing solution to a wellbore in the formation and for delivering an output laser beams to the rock formation.
Claims
1. A tool for perforating a wellbore in a downhole environment within a rock formation, the tool comprising: a perforation unit disposed within an elongated body of the tool, the perforation unit comprising: a pipe transferring a fracturing solution, wherein the pipe extends within the elongated body of the tool; and a nozzle in fluid connection with the pipe, the nozzle for discharging the fracturing solution to the wellbore and for controlling a flow of the fracturing solution, and a laser unit disposed within an elongated body of the tool, the laser unit comprising: an optical transmission media disposed within the pipe and passing a raw laser beam generated from a laser generator, wherein the optical transmission media extends within an elongated body of the tool, and wherein the optical transmission media and the pipe are disposed coaxially relative to a longitudinal axis of the elongated body; and a laser head coupled to the optical transmission media, the laser head receiving the raw laser beam from the optical transmission media, wherein the laser head comprises an optical assembly controlling at least one characteristic of an output laser beam.
2. The tool of claim 1, wherein the optical transmission media comprises one or more casings thereon.
3. The tool of claim 2, wherein the one or more casings are configured to resist downhole pressure.
4. The tool of claim 2, wherein the one or more casings comprise an insulating casing for insulating the optical transmission media from the fracturing solution.
5. The tool of claim 1, wherein the fracturing solution comprises an acid selected from the group consisting of hydrofluoric acid (HF), hydrochloric acid (HCl), hydrobromic acid (HBr), hydroiodic acid (HI), hypochlorous acid (HClO), chlorous acid (HClO.sub.2), chloric acid (HClO.sub.3), perchloric acid (HClO.sub.4), hypobromic acid (HBrO), bromous acid (HBrO.sub.2), chloric acid (HBrO.sub.3), perbromic acid (HBrO.sub.4), hypoiodous acid (HIO), iodous acid (HIO.sub.2), iodic acid (HIO.sub.3), periodic acid (HIO.sub.4), hypofluorous acid (HFO), sulfuric acid (H.sub.2SO.sub.4), fluorosulfuric acid (HSO.sub.3F), nitric acid (HNO.sub.3), phosphoric acid (H.sub.3PO.sub.4), fluoroantimonic acid (HSbF.sub.6), fluoroboric acid (HBF.sub.4), hexafluorophosphoric acid (HPF.sub.6), chromic acid (H.sub.2CrO.sub.4), boric acid (H.sub.3BO.sub.3), formic acid (HCOOH), acetic acid (CH.sub.3COOH), methanesulfonic acid (CH.sub.3SO.sub.3H), ethylenediaminetetraacetic acid (EDTA), glutamic diacetic acid (GLDA), and combinations thereof.
6. The tool of claim 1, wherein the rock formation comprises sandstone and the fracturing solution comprises HCl.
7. The tool of claim 1, wherein the rock formation comprises clay and the fracturing solution comprises HF.
8. The tool of claim 1, wherein the perforation unit comprises a plurality of the nozzles.
9. The tool of claim 8, wherein the plurality of the nozzles are spaced along a length of the elongated body.
10. The tool of claim 8, wherein the plurality of the nozzles are radially off-set at a regular angular interval.
11. The tool of claim 10, wherein the regular angular interval is about 15, 30, 45, 60, 90, 120, 135, 150, or 180 degrees.
12. The tool of claim 1, wherein the laser unit comprises a purging assembly disposed at least partially within or adjacent to the laser head, wherein the purging assembly delivers a purging fluid to an area proximate the output laser beam.
13. The tool of claim 12, wherein the purging assembly comprises purging nozzles, at least a portion of the purging nozzles being vacuum nozzles connected to a vacuum source, and the purging nozzles for removing debris and/or gaseous fluids from the area proximate the output laser beam when vacuum is applied.
14. The tool of claim 1, the laser unit further comprises an orientation nozzle disposed about an outer circumference of the laser head, wherein the orientation nozzle controls motion and orientation of the laser head within the wellbore.
15. The tool of claim 14, wherein the orientation nozzle is a purging nozzle providing thrust to the laser head for movement within the wellbore.
16. The tool of claim 14, wherein the orientation nozzle is movably coupled to the laser head thereby allowing the orientation nozzle to rotate or pivot relative to the laser head, and the orientation nozzle provides forward motion, reverse motion, rotational motion, or combinations thereof to the laser head relative to the tool.
17. The tool of claim 1, further comprising a centralizer coupled to the tool, wherein the centralizer holds the tool in the wellbore.
18. The tool of claim 1, wherein the tool comprises a plurality of centralizers disposed on the elongated body, and a first portion of the plurality of centralizers is disposed forward of the perforation unit and a second portion of the plurality of centralizers is disposed aft of the perforation unit.
19. The tool of claim 1, wherein the nozzle is configured to direct the fracturing liquid into one or more perforations in the rock formation formed by the output laser beam so as to create a network of fractures in the wellbore.
20. A tool for perforating a wellbore in a downhole environment within a rock formation, the tool comprising: a perforation unit disposed within an elongated body of the tool, the perforation unit comprising: a pipe transferring a fracturing solution comprising acid, wherein the pipe extends within the elongated body of the tool; and a plurality of nozzles in fluid connection with the pipe, the plurality of nozzles for discharging the fracturing solution to the wellbore and for controlling a flow of the fracturing solution, and a laser unit disposed within the elongated body of the tool, the laser unit comprising: an optical transmission media disposed within the pipe and passing a raw laser beam generated from a laser generator, wherein the optical transmission media extends within an elongated body of the tool, and wherein the optical transmission media and the pipe are disposed coaxially relative to a longitudinal axis of the elongated body; and a laser head coupled to the optical transmission media, the laser head receiving the raw laser beam from the optical transmission media, wherein the laser head comprises an optical assembly controlling at least one characteristic of an output laser beam.
21. A method of using a tool for perforating a wellbore, the method comprises steps of: positioning the tool within a wellbore within a rock formation, the tool comprising: a perforation unit disposed within an elongated body of the tool, the perforation unit comprising: a pipe transferring a fracturing solution, wherein the pipe extends within the elongated body of the tool; and a nozzle in fluid connection with the pipe, the nozzle for discharging the fracturing solution to the wellbore and for controlling a flow of the fracturing solution; a laser unit disposed within the elongated body of the tool, the laser unit comprising: an optical transmission media disposed within the pipe and passing a raw laser beam generated from a laser generator, wherein the optical transmission media extends within an elongated body of the tool, and wherein the optical transmission media and the pipe are disposed coaxially relative to a longitudinal axis of the elongated body; and a laser head coupled to the optical transmission media, the laser head receiving the raw laser beam from the optical transmission media, wherein the laser head comprises an optical assembly controlling at least one characteristic of an output laser beam, selecting the fracturing solution based on composition of the rock formation; delivering the output laser beams to the rock formation; and discharging the fracturing solution to the rock formation.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the disclosed systems and methods and are not intended as limiting. For purposes of clarity, not every component may be labeled in every drawing. In the following description, various embodiments are described with reference to the following drawings, in which:
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DETAILED DESCRIPTION
(11)
(12) The centralizers 36 can be disposed at various points along the elongated body 28 as need to suit a particular application. The centralizers 36 can also help support the weight of the stimulation tool 20 and can be spaced along the elongated body 28 as needed to accommodate the stimulation tool 20 extending deeper into the formation. The centralizers 36 may include an elastomeric material that expands when wet, bladders that inflate hydraulically or pneumatically from the ground, or by other mechanical means.
(13) As further shown in
(14)
(15) Nozzles 70 at the exit ports 34 are fluidly connected to the pipe 72, so that the nozzles 70 may discharge the fracturing solution received from the pipe 72. The stimulation tool 20 may generate a network of fractures, for example, acid-induced fractures, in the wellbore by injecting the fracturing solution as shown in
(16) In some embodiments, the stimulation tool 20 includes one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, thirteen, fourteen, fifteen, sixteen, seventeen, eighteen, nineteen, or twenty nozzles 70. In some embodiments, the flow rate of each of the nozzles 70 may be substantially (for example, within about 1% of, within about 5% of, and/or within about 10% of) similar. In some embodiments, the flow duration of each of the nozzles 70 may be substantially (for example, within about 1% of, within about 5% of, and/or within about 10% of) similar. In some embodiments, each nozzle 70 may have different flow rate, direction and/or flow duration.
(17) In some embodiments, the fracturing solution includes acid. The acid used with the technologies described may be selected from the group consisting of hydrofluoric acid (HF), hydrochloric acid (HCl), hydrobromic acid (HBr), hydroiodic acid (HI), hypochlorous acid (HClO), chlorous acid (HClO.sub.2), chloric acid (HClO.sub.3), perchloric acid (HClO.sub.4), hypobromic acid (HBrO), bromous acid (HBrO.sub.2), chloric acid (HBrO.sub.3), perbromic acid (HBrO.sub.4), hypoiodous acid (HIO), iodous acid (HIO.sub.2), iodic acid (HIO.sub.3), periodic acid (HIO.sub.4), hypofluorous acid (HFO), sulfuric acid (H.sub.2SO.sub.4), fluorosulfuric acid (HSO.sub.3F), nitric acid (HNO.sub.3), phosphoric acid (H.sub.3PO.sub.4), fluoroantimonic acid (HSbF.sub.6), fluoroboric acid (HBF.sub.4), hexafluorophosphoric acid (HPF.sub.6), chromic acid (H.sub.2CrO.sub.4), boric acid (H.sub.3BO.sub.3), formic acid (HCOOH), acetic acid (CH.sub.3COOH), methanesulfonic acid (CH.sub.3SO.sub.3H), ethylenediaminetetraacetic acid (EDTA), glutamic diacetic acid (GLDA), and combinations thereof.
(18) The acid may be selected depending on compositions of the rock formation. For example, if the rock formation includes sandstone, the fracturing solution may include HCl, organic acid (for example, formic acid (HCOOH), acetic acid (CH.sub.3COOH), methanesulfonic acid (CH.sub.3SO.sub.3H)) and/or chelating agent (for example, ethylenediaminetetraacetic acid (EDTA), glutamic diacetic acid (GLDA)). An exemplary reaction is shown in the below chemical reaction Formula 1.
2HCl+CaCO.sub.3.fwdarw.CaCl.sub.2+H.sub.2O+CO.sub.2 Chemical Reaction Formula 1
(19) If the rock formation includes clay, the fracturing solution may include HF. An exemplary reaction is shown in the below chemical reaction Formula 2.
26HF+Al.sub.2Si.sub.4O.sub.10(OH).sub.2+4HCl.fwdarw.4H.sub.2SiF.sub.6+2AlF.sub.2++12H.sub.2O+4Cl.sup.− Chemical Reaction Formula 2
(20) In some embodiments, a flow rate of the fracturing solution is between 400 liters per minute (l/min) and 10,000 l/min. In some embodiments, for example, for acid fracturing, the volume of solution used may be between 230 m.sup.3 and 320 m.sup.3 (about 1,500-2,000 barrels (bbl)), and the solution flow rate may be between 3,000 l/min and 7,000 l/min (about 20-45 bbl/min). In some embodiments, for example, for matrix acidizing, the volume of solution used may be about 230 m.sup.3 (about 1,500 bbl), and the flow rate may be between 4,70 l/min and 1,600 l/min (about 3-10 bbl/min).
(21) In some embodiments, a molarity of the fracturing is within a range from about 1M to about 30M. In some embodiments, a molarity of the dissolving solution is within a range from about 1M to about 20M. In some embodiments, a molarity of the dissolving solution is within a range from about 1M to about 10M. In some embodiments, a morality of a dissolving solution is within a range of about 1M to about 5M. In some embodiments, a molarity of the dissolving solution is within a range from about 5M to about 30M. In some embodiments, a molarity of the dissolving solution is within a range from about 10M to about 30M. In some embodiments, a molarity of the dissolving solution is within a range from about 20M to about 30M.
(22) The optical transmittal media 27 (or fiber optic cable) may be coupled with a laser head 38 (see
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(24) Referring back to
(25) The laser head 38 is depicted in detail in
(26) The optical assembly 40 shown in
(27) In addition, the laser head 38 may also include a plurality of orientation nozzles 44 and a plurality of purging nozzles 46. The purging nozzles 46 are disposed inside the head 38 for cooling the optical assembly and/or preventing any back-flow of debris into the head 38. Water or a hydrocarbon fluid, or generally any fluid or gas that is non-damaging and transparent to the laser beam, can be used to remove the debris. The purge fluid 58 can flow through channels 59 disposed within the laser head 38. In accordance with various embodiments, a portion of the purging nozzles 46 may be vacuum nozzles connected to a vacuum source and adapted to remove debris and gaseous fluids from around or within the laser head 38.
(28) The orientation nozzles 44 may be located on an outer surface of the laser head 38. In the embodiment, there are four (4) orientation nozzles 44 shown disposed on and evenly spaced about an outer circumference of the laser head 38. A laser head 38 may be configured as deployable perforation unit 32. However, different quantities and arrangements of the orientation nozzles 44 are possible to suit a particular application. For example, if the orientation nozzles 44 are used to assist with deploying a perforation unit 32 from the elongated body 28, there may be additional orientation nozzles 44 disposed on the laser head 38.
(29) Generally, the laser head 38 may be oriented by controlling a flow of a fluid (either liquid or gas) through the orientation nozzles 44. For example, by directing the flow of the fluid in a rearward direction 45 as shown in
(30) As shown in
(31) In various embodiments, the orientation nozzles 44 may be fixedly connected to the laser head 38 for limited motion control or be movably mounted to the laser head 38 for essentially unlimited motion control of the perforation unit 32. In one embodiment, the orientation nozzles 44 are movably mounted to the laser head 38 via servo motors with swivel joints that may control whether the openings 43 face rearward (forward motion), forward (reverse motion), or at an angle to a central axis 47 (rotational motion or a combination of linear and rotational motion depending on the angular displacement of the orientation nozzle 44 relative to the central axis 47). For example, if the orientation nozzles 44 are aligned perpendicular to the central axis 47, the orientation nozzles 44 may only provide rotational motion. If the orientation nozzles 44 are parallel to the central axis 47, then the orientation nozzles 44 may only provide linear motion. A combination of rotational and linear motion is provided for any other angular position relative to the central axis 47. The fluid lines for providing the thrust may be coupled to the nozzles via swivel couplings as known in the art.
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(33) The laser still requires one or more fluids, but these fluids are used to purge and clean the hole from the debris, opening up a path for the laser beam, and to orient the laser head 38.
(34) In various embodiments, the stimulation tool 20 is introduced into the wellbore 24 via a coiled tubing unit that provides a reel, power and fluid for the tool, and host all of the laser supporting equipment. The laser source may be also coupled to the coiled tubing unit. The laser generator 30 is switched off while the laser perforation tool 20 is being inserted into the wellbore 24. Once the stimulation tool 20 reaches the target, typically an open hole, the centralizers 36 may inflate to centralize the tool at that location and the laser may turn on along with the source of purge fluid 58 for the purging nozzles 46 and orientation nozzles 44, if included.
(35) In various embodiments, a diameter of the optical transmittal media 27, with shielding is within the range of one (1) inch (or about 2.5 cm) to five inches (or about 12.5 cm).
(36) In some embodiments, the stimulation tool 20 has sensors to monitor and control the stimulation process. The first, second, third, and fourth sensors 66, 68, 70, 72 may include electronic transmitters, receivers, and/or transceivers, RFID tags and receivers, proximity sensors, strain gauges, Hall sensors, temperature probes, static pressure transmitters, differential pressure transmitters, moisture sensors, accelerometers, and other types of sensors.
(37) One advantage of using high power laser technology is the ability to create controlled non-damaged, clean holes for various types of the rock. The laser perforation tools disclosed herein have capability to penetrate in many types of rocks having various rock strengths and stress orientations, as shown in the graph of
(38) In general, the construction materials of the stimulation tool 20 may be of materials that are resistant to the high temperatures, pressures, and vibrations that may be experienced within an existing wellbore, and that can protect the system from fluids, dust, and debris. One of ordinary skill in the art will be familiar with suitable materials.
(39) The laser generator 30 may excite energy to a level greater than a sublimation point of the hydrocarbon bearing formation, which is output as the raw laser beam. The excitation energy of the raw laser beam required to sublimate the hydrocarbon bearing formation can be determined by one of skill in the art. In some embodiments, the laser generator 30 may be tuned to excite energy to different levels as required for different hydrocarbon bearing formations. The hydrocarbon bearing formation may include limestone, shale, sandstone, or other rock types common in hydrocarbon bearing formations. The discharged laser beam may penetrate a wellbore casing, cement, and hydrocarbon bearing formation to form, for example, holes or tunnels.
(40) The laser generator 30 may be of laser unit capable of generating high power laser beams, which may be conducted through an optical transmittal media 27, such as, for example, lasers of ytterbium, erbium, neodymium, dysprosium, praseodymium, and thulium ions. In some embodiments, the laser generator 30 includes, for example, a 5.34-kW Ytterbium-doped multi-clad fiber laser. In some embodiments, the laser generator 30 may be of laser capable of delivering a laser at a minimum loss. The wavelength of the laser generator 30 may be determined by one of skill in the art as necessary to penetrate hydrocarbon bearing formations.
(41) At least part of the stimulation tool 20 and its various modifications may be controlled, at least in part, by a computer program product, such as a computer program tangibly embodied in one or more information carriers, such as in one or more tangible machine-readable storage media, for execution by, or to control the operation of, data processing apparatus, for example, a programmable processor, a computer, or multiple computers, as would be familiar to one of ordinary skill in the art.
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(43) It is contemplated that systems, devices, methods, and processes of the present application encompass variations and adaptations developed using information from the embodiments described in the following description. Adaptation or modification of the methods and processes described in this specification may be performed by those of ordinary skill in the relevant art.
(44) Throughout the description, where compositions, compounds, or products are described as having, including, or comprising specific components, or where processes and methods are described as having, including, or comprising specific steps, it is contemplated that, additionally, there are articles, devices, and systems of the present application that consist essentially of, or consist of, the recited components, and that there are processes and methods according to the present application that consist essentially of, or consist of, the recited processing steps.
(45) It should be understood that the order of steps or order for performing certain actions is immaterial, so long as the described method remains operable. Moreover, two or more steps or actions may be conducted simultaneously.