Degradable wellbore isolation devices with large flow areas
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E21B-033/12
E21B-033/129
C22C-023/02
C22C-023/04
E21B-033/13
E21B-043/26
C09K-008/42
C22C-021/00
E21B-033/134
출원번호
US-0758989
(2014-08-28)
등록번호
US-9982506
(2018-05-29)
국제출원번호
PCT/US2014/053212
(2014-08-28)
국제공개번호
WO2016/032493
(2016-03-03)
발명자
/ 주소
Walton, Zachary
Fripp, Michael Linley
Jurgensmeier, Michael James
Murphree, Zachary
출원인 / 주소
Halliburton Energy Services, Inc.
대리인 / 주소
McDermott Will & Emery LLP
인용정보
피인용 횟수 :
0인용 특허 :
16
초록▼
An example downhole tool for use in a wellbore lined with casing includes a wellbore isolation device that provides a plurality of components including a mandrel that defines a central flow passage that allows fluid flow in at least one direction through the wellbore isolation device, the wellbore i
An example downhole tool for use in a wellbore lined with casing includes a wellbore isolation device that provides a plurality of components including a mandrel that defines a central flow passage that allows fluid flow in at least one direction through the wellbore isolation device, the wellbore isolation device providing an inner diameter and an outer diameter. A minimum production flow area is provided across the wellbore isolation device and is determined by at least one of: a flow area across the wellbore isolation device that is at least 1/16 a total flow area of the casing at a location of the wellbore isolation device within the wellbore, and a flow area resulting from the inner diameter being at least 25% of the outer diameter. At least the mandrel is made of a slowly degradable material that degrades when exposed to a wellbore environment.
대표청구항▼
1. A downhole tool for use in a wellbore lined with casing, comprising: a wellbore isolation device that provides a plurality of components including a mandrel that defines a central flow passage that allows fluid flow in at least one direction through the wellbore isolation device, the wellbore iso
1. A downhole tool for use in a wellbore lined with casing, comprising: a wellbore isolation device that provides a plurality of components including a mandrel that defines a central flow passage that allows fluid flow in at least one direction through the wellbore isolation device, the wellbore isolation device providing an inner diameter and an outer diameter,wherein a minimum production flow area is provided across the wellbore isolation device and is determined by at least one of: a flow area across the wellbore isolation device that is at least 1/16 a total flow area of the casing at a location of the wellbore isolation device within the wellbore; anda flow area resulting from the inner diameter being at least 25% of the outer diameter,wherein the inner diameter comprises a diameter of the central flow passage, and the outer diameter comprises a diameter of the wellbore isolation device in an unexpanded configuration, andwherein at least the mandrel is made of a slowly degradable material that degrades when exposed to a wellbore environment. 2. The downhole tool of claim 1, wherein the wellbore isolation device is selected from the group consisting of a frac plug, a wellbore packer, a deployable baffle, or any combination thereof. 3. The downhole tool of claim 1, wherein the flow area across the wellbore isolation device includes any fluid flow area through the central flow passage and through any other flow paths through or around the wellbore isolation device. 4. The downhole tool of claim 3, wherein the other flow paths comprise at least one flow channel defined longitudinally through the mandrel through which fluids may flow. 5. The downhole tool of claim 1, wherein the minimum production flow area of the wellbore isolation device is determined by a combination of: a flow area across the wellbore isolation device that is at least 1/9 of the total flow area of the casing at the location of the wellbore isolation device within the wellbore; anda flow area resulting from the inner diameter being at least 33% of the outer diameter. 6. The downhole tool of claim 1, wherein one or more of the plurality of components are made of the slowly degradable material, the plurality of components selected from the group consisting of a frac ball, a slip, a slip wedge, a packer element, a mule shoe, and any combination thereof. 7. The downhole tool of claim 1, wherein the slowly degradable material comprises a material that exhibits a dissolution rate between 0.01 mg/cm2 per hour and 10 mg/cm2 per hour at a temperature of 200° F. while exposed to a 15% potassium chloride (KCl) solution. 8. The downhole tool of claim 1, wherein the slowly degradable material comprises a material that loses between 0.1% and 10% of its total mass per day at 200° F. in 3% potassium chloride (KCl) solution. 9. The downhole tool of claim 1, wherein the degradable material is a galvanically-corrodible metal or metal alloy. 10. The downhole tool of claim 9, wherein the galvanically-corrodible metal or metal alloy is selected from the group consisting of aluminum, iron, zinc, magnesium, a magnesium alloy, beryllium, and any alloy thereof. 11. The downhole tool of claim 10, wherein the magnesium alloy includes magnesium at a concentration in a range of about 70% to about 98%. 12. The downhole tool of claim 10, wherein the magnesium alloy includes magnesium and a metal selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, beryllium, calcium, strontium, barium, aluminum, gallium, indium, tin, thallium, lead, bismuth, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, praseodymium, silver, lanthanum, hafnium, tantalum, tungsten, terbium, rhenium, osmium, iridium, platinum, gold, neodymium, gadolinium, erbium, oxides of any of the foregoing, and any combinations thereof. 13. The downhole tool of claim 10, wherein the magnesium alloy includes magnesium and a non-metal selected from the group consisting of graphite, carbon, silicon, boron nitride, and any combinations thereof. 14. The downhole tool of claim 10, wherein the magnesium alloy is selected from the group consisting of: 4.8% to 6.2% zinc, a minimum 0.45% zirconium, up to 0.3% impurities, and balance magnesium;7.8% to 9.2% aluminum, 0.2% to 0.8% zinc, 0.12% manganese, up to 0.015% impurities, and balance magnesium;2.5% to 3.5% aluminum, 0.7% to 1.3% zinc, 0.2% manganese, up to 0.15% impurities, and balance magnesium; andany combinations thereof. 15. The downhole tool of claim 1, wherein the wellbore isolation device exhibits a density selected from the group consisting of: a density that is less than 2 g/cm3 when the slowly degradable material is a magnesium alloy;a density that is less than 3 g/cm3 when the slowly degradable material is magnesium or an aluminum alloy;a density that is less than 5 g/cm3 when the slowly degradable material is a material that is lighter than steel;and any combinations thereof. 16. The downhole tool of claim 1, further comprising a sheath disposed on all or a portion of at least one of the plurality of components, the sheath comprising a material selected from the group consisting of a TEFLON® coating, a wax, a drying oil, a polyurethane, an epoxy, a crosslinked partially hydrolyzed polyacrylic, a silicate material, a glass, an inorganic durable material, a polymer, polylactic acid, polyvinyl alcohol, polyvinylidene chloride, a hydrophobic coating, paint, and any combination thereof. 17. A method, comprising: introducing a wellbore isolation device into a wellbore lined at least partially with casing, the wellbore isolation device providing a plurality of components including a mandrel that defines a central flow passage that allows fluid flow in at least one direction through the wellbore isolation device, wherein at least the mandrel is made of a slowly degradable material;anchoring the wellbore isolation device within the casing at a target location, the wellbore isolation device providing an inner diameter and an outer diameter;performing at least one downhole operation;degrading at least the mandrel upon exposing the wellbore isolation device to a wellbore environment; andcommencing production operations within the wellbore, wherein a minimum production flow area is provided across the wellbore isolation device and is determined by at least one of: a flow area across the wellbore isolation device that is at least 1/16 a total flow area of the casing at a location of the wellbore isolation device within the wellbore; anda flow area resulting from the inner diameter being at least 25% of the outer diameter. 18. The method of claim 17, wherein the wellbore isolation device is selected from the group consisting of a frac plug, a wellbore packer, a deployable baffle, or any combination thereof. 19. The method of claim 17, wherein the minimum production flow area of the wellbore isolation device is determined by a combination of: a flow area across the wellbore isolation device that is at least 1/9 of the total flow area of the casing at the location of the wellbore isolation device within the wellbore; anda flow area resulting from the inner diameter being at least 33% of the outer diameter. 20. The method of claim 17, wherein one or more of the plurality of components are made of the slowly degradable material, the method further comprising degrading the one or more of the plurality of components upon exposing the wellbore isolation device to the wellbore environment. 21. The method of claim 17, wherein degrading at least the mandrel comprises degrading the mandrel at a dissolution rate between 0.01 mg/cm2 per hour and 10 mg/cm2 per hour at a temperature of 200° F. while exposed to a 15% potassium chloride (KCl) solution. 22. The method of claim 17, wherein degrading at least the mandrel comprises losing between 0.1% and 10% of a total mass of the mandrel per day at 200° F. in 3% potassium chloride (KCl) solution. 23. The method of claim 17, wherein the degradable material is a galvanically-corrodible metal or metal alloy selected from the group consisting of gold, a gold-platinum alloy, silver, nickel, a nickel-copper alloy, a nickel-chromium alloy, copper, a copper alloy, chromium, tin, aluminum, iron, zinc, magnesium, a magnesium alloy, beryllium, and any alloy thereof. 24. A hydraulic frac plug, comprising: a mandrel having a central flow passage defined therethrough and providing an inner diameter and an outer diameter;one or more packer elements disposed about the mandrel and expandable to seal against casing secured within a wellbore;an upper slip wedge and a lower slip wedge each disposed about the mandrel on opposing sides of the one or more packer elements; andan upper slip and a lower slip each disposed about the mandrel on opposing sides of the one or more packer elements and actuatable to anchor the hydraulic frac plug within the casing, wherein at least the mandrel is made of a slowly degradable material that degrades when exposed to a wellbore environment,wherein a minimum production flow area is provided across the hydraulic frac plug and is determined by at least one of: a flow area across the hydraulic frac plug that is at least 1/16 a total flow area of the casing at a location of the hydraulic frac plug within the wellbore; anda flow area resulting from the inner diameter being at least 25% of the outer diameter, andwherein the inner diameter comprises a diameter of the central flow passage, and the outer diameter comprises a diameter of the hydraulic frac plug in an unexpanded configuration. 25. The hydraulic frac plug of claim 24, wherein the minimum production flow area of the hydraulic frac plug is determined by a combination of: a flow area across the hydraulic frac plug that is at least 1/9 of the total flow area of the casing at the location of the hydraulic frac plug within the wellbore; anda flow area resulting from the inner diameter being at least 33% of the outer diameter. 26. The hydraulic frac plug of claim 24, wherein the slowly degradable material comprises a material that exhibits a dissolution rate between 0.01 mg/cm2 per hour and 10 mg/cm2 per hour at a temperature of 200° F. while exposed to a 15% potassium chloride (KCl) solution. 27. The hydraulic frac plug of claim 24, wherein the slowly degradable material comprises a material that loses between 0.1% and 10% of its total mass per day at 200° F. in 3% potassium chloride (KCl) solution. 28. The hydraulic frac plug of claim 24, wherein the degradable material is a galvanically-corrodible metal or metal alloy selected from the group consisting of gold, a gold-platinum alloy, silver, nickel, a nickel-copper alloy, a nickel-chromium alloy, copper, a copper alloy, chromium, tin, aluminum, iron, zinc, magnesium, a magnesium alloy, beryllium, and any alloy thereof. 29. The hydraulic frac plug of claim 28, wherein the magnesium alloy includes magnesium at a concentration in a range of about 70% to about 98%. 30. The hydraulic frac plug of claim 28, wherein the magnesium alloy includes magnesium and a metal selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, beryllium, calcium, strontium, barium, aluminum, gallium, indium, tin, thallium, lead, bismuth, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, praseodymium, silver, lanthanum, hafnium, tantalum, tungsten, terbium, rhenium, osmium, iridium, platinum, gold, neodymium, gadolinium, erbium, oxides of any of the foregoing, and any combinations thereof. 31. The hydraulic frac plug of claim 24, wherein the magnesium alloy is selected from the group consisting of: 4.8% to 6.2% zinc, a minimum 0.45% zirconium, up to 0.3% impurities, and balance magnesium;7.8% to 9.2% aluminum, 0.2% to 0.8% zinc, 0.12% manganese, up to 0.015% impurities, and balance magnesium;2.5% to 3.5% aluminum, 0.7% to 1.3% zinc, 0.2% manganese, up to 0.15% impurities, and balance magnesium; andany combinations thereof. 32. The hydraulic frac plug of claim 24, wherein the hydraulic frac plug exhibits a density selected from the group consisting of: a density that is less than 2 g/cm3 when the slowly degradable material is a magnesium alloy;a density that is less than 3 g/cm3 when the slowly degradable material is magnesium or an aluminum alloy;a density that is less than 5 g/cm3 when the slowly degradable material is a material that is lighter than steel; andany combinations thereof.
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