SUBTERRANEAN BARRIER, SYSTEM AND METHOD OF USE
An orientable frac ball for substantially sealing a subterranean formation. Desired orientation can be accomplished by altering the geometry of the ball with one or more features that can be molded with or added to the ball. A projection of any shape on a ball with a length plus ball diameter that is greater than the inner diameter of the well bore will prevent the ball from orienting in an undesired position on the seat. This projection can be made of various materials that break or disintegrate when desired to remove the ball from the well bore. During the pump back process in which the balls will need to move through the progressively larger sealing seats, the projection should not hinder the removal process. It will break away or off the ball during this process. Break up features can easily be added to these tail sections. These balls can be dropped with the tail down or tail up. Alternatively, a magnet placed in the frac ball can orient the ball on a metal seat by magnetic attraction.
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The present invention relates generally to barriers for sealing zones in subterranean wells and, more particularly, to composite fracturing balls and methods of use.
SUMMARY OF THE INVENTIONThe present invention is directed to a barrier for substantially sealing a zone in a subterranean formation, the barrier comprising a body and a projection connectable with the body.
The present invention further is directed to a system for substantially sealing a zone in a subterranean formation, the system comprising a barrier, wherein the barrier comprises a body, and a projection connectable with the body.
The present invention further is directed to a method of substantially sealing a zone in a subterranean formation, the subterranean formation comprising at least one seat. The method comprises the steps of orienting a barrier comprising a body and a projection connectable with the body so that the barrier is substantially sealingly receivable in the seat.
The present invention further is directed to a method of substantially sealing a zone in a subterranean formation, the subterranean formation comprising at least one seat, the method comprising the steps of orienting a barrier comprising a body and a magnet so that the barrier is substantially sealingly receivable in the seat.
The present invention further is directed to a system for substantially sealing a zone in a subterranean formation. The system comprises a body and a magnet connectable with the body.
Graduated ball drop systems are used in oil and gas field operations for various purposes, such as isolating a zone in a subterranean well for fracturing or stimulation treatment. Certain of these systems typically employ a series of underground sliding sleeves and are applicable in horizontal, vertical or deviated wells. The sliding sleeve is set in motion by a ball inserted into the well from the surface via pump, gravity or other transport, to a desired depth and location in the well. When the ball reaches a predetermined location, it engages a sealing seat, thereby creating pressure that moves the sleeve and acting as a barrier to isolate the subterranean formation beyond the location of the ball.
Various types of balls, often called fracturing or frac balls, can be used in graduated ball drop systems. These balls are made of a variety of materials, including metals, metal alloys, resins, composites and other non-metallic substances. The material chosen for any particular application is in part a function of the desired compressive strength of the ball. It also is desirable to choose a material that facilitates removal of the ball from the seat following completion of well stimulation or other treatment. To that end, nonmetallic materials create a lighter weight, more maneuverable ball and are easier to remove from the seat during flowback operations or clean up. Balls made from non-metallic materials also can be purposefully susceptible to rupture, dispersion or dissolution in well fluids, which further facilitates removal from the seat and well.
Consequently, non-metallic materials provide benefits over metals and metal alloys in graduated ball drop systems. Such non-metallic materials include reinforced layered or rolled laminate or polymer matrices that are reinforced with glass or carbon strands or fibers. While these materials provide desirable physical properties and produce effective results, they still do not entirely satisfy the requirements needed for frac balls in high pressure fracturing processes.
In order to be effective, frac balls must withstand high pressures. To date, the highest performing non-metallic frac balls are machined from composite materials with fiber reinforcements. The reinforcements in these composite materials may be formed from materials having reinforcing fibers randomly oriented in a bonding matrix, such as from a sheet molding compound or bulk molding compound, as shown in
Composite frac balls, whether machined from billet, flat or round stock, have proven to be stronger in one direction versus another. When loaded in the direction that puts in shear, for example, the (1) interlaminate plies of the composite material, (2) the parting line of the molded frac ball (3) or the fibers themselves, whether chopped and/or continuous, as shown in
Composite frac balls generally perform better when the points that are susceptible to shear are oriented generally perpendicular to the direction of flow of fluids, shown by arrow z in the well in
Frac balls made from composite materials can only be performance rated based on test data generated from the balls employed in the least desired position on the seat, because heretofore orientation of the ball downhole was uncontrollable. Consequently, there is a need for an orientable composite frac ball that enables consistent orientation in a desired position on the sealing seat downhole.
The present invention provides an orientable frac ball, system and method of use that position the ball in a desired orientation on the sealing seat, thus avoiding the above-described problems. Desired orientation can be accomplished by altering the geometry of the ball with one or more features that can be molded with or added to the ball. A projection of any geometry on a ball, with a length plus ball diameter that is greater than the diameter of well bore, will prevent the ball from orienting in an undesired position on the seat. This projection may be made of a variety of materials that can break or disintegrate at the appropriate time when removing the frac ball from the well bore. During the pump back process in which the frac ball will move up the well through the progressively larger sealing seats, the projection will break away and should not hinder the removal process. The projection may comprise failure points for strategically breaking the projection during specified operations such as pump back. These frac balls can be dropped with the tail down or tail up. As an alternative to a projection, a magnet strategically placed in the frac ball can orient the ball on a metal seat by magnetic attraction with the sealing seat. These and other advantages of the present invention will be apparent from the following description of the invention.
Turning now to the drawings in general, and to
With continuing reference to
The body 18 of frac ball 12 may be comprised of any material suitable for use downhole in well 14, including fiberglass, carbon, polymers, plastics, thermoplastic resins, thermoset resins, metals, metal alloys, cloth, composites and combinations of the foregoing. In one embodiment of the invention, the body 18 of frac ball 12 comprises a reinforcing material of chopped glass or carbon fibers in a bismaleimide (BMI) resin matrix. In another embodiment of the invention, the body 18 of frac ball 12 comprises a laminated composite material of fiberglass cloth and epoxy or phenolic compound. It will be appreciated that the body 18 may be comprised of any materials suitable to the particular pressures, temperatures, fluids and other conditions at the well 14 where in use. Although the frac ball of the present invention can be sized to any application, the diameter of body 18 of frac ball 12 may range from about 0.75 inches to about 4 inches. The body 18 generally has a density of from about 62 lb/ft3 (1 g/cm3) to about 500 lb/ft3 (7.85 g/cm3).
With continuing reference to
The geometry of the projection 20 helps achieve the desired orientation of the frac ball 12 on the sealing seat 16. As shown in
Length of Projection (LP)+Length of Body in the Direction Flow (LB)>Inner Diameter of Well (IDW)
Because the total length of the frac ball 12 as described above, including the projection and the body, is greater that the inner diameter of the well 14, the projection 20 prohibits the frac ball 12 from rotating in the well bore 14 during placement, thus maintaining orientation of the frac ball 20 in substantially the same orientation as when the frac ball is inserted into the well 14. When the body 18 of the frac ball 12 is a sphere or torus, the length of the body is the same as the diameter of the sphere or torus. However, when the body 18 of the frac ball 12 is a polyhedra, the length of the body is determined by the distance between the two outermost vertices of the body as positioned downhole in the direction of flow. For a cylinder or cone, the length of the body 18 is the height of the cylinder or cone.
The projection 20 may be formed integrally with the body 18, as shown in
In one embodiment of the invention, the projection 20 is comprised of a material that dissolves or breaks during pump back operations or when it otherwise is desired to remove the frac ball 12 from the well 14. During the pump back process, in which the frac ball 12 will move through progressively larger seats 16 up the well 14 toward the surface, the projection 20 does not hinder the removal of the projection 20 from the well 14 when it breaks or dissolves from the body 18. To that end, the projection 20 may further comprise serrations or perforations 26 as shown in
It will be appreciated that frac ball 12 further may comprise a plurality of projections, an exemplar of which is shown
The projection 20 may be solid or it may comprise a porous substance to make the projection lighter in weight and more maneuverable downhole. Additionally, a porous projection 20 may be more susceptible to breakage or dissolution in a soluble substance thereby facilitating removal from the wellbore 14. It now will be appreciated that the projection 20 alters the geometry of the frac ball 12 and orients the body 18 with respect to the z axis of the well 14.
The frac ball 12 of the present invention also or alternatively may comprise a magnet 40, shown in
With continuing reference to
Turning again to
It now will be appreciated that the subject invention provides an effective apparatus and means of controlling the orientation of a frac ball and particularly a composite frac ball on the sealing seat of a well. The present invention overcomes difficulties associated with controlling orientation of composite frac balls and provides a method of use.
The invention of this application has been described above both generically and with regard to specific embodiments. Although the invention has been set forth in what has been believed to be preferred embodiments, a wide variety of alternatives known to those of skill in the art can be selected with a generic disclosure. Changes may be made in the combination and arrangement of the various parts, elements, steps and procedures described herein without departing from the spirit and scope of the invention as defined in the following claims.
Claims
1. A barrier for substantially sealing a zone in a subterranean formation, the barrier comprising:
- a body; and
- a projection connectable with the body.
2. The barrier of claim 1 wherein the body is comprised of a material that is selected from the group consisting of fiberglass, carbon, polymers, thermoplastic resins, thermoset resins, metals, cloth, composites, and combinations of any of the foregoing.
3. The barrier of claim 1 wherein the body comprises a laminated composite material.
4. The barrier of claim 1 where in the body comprises a randomly oriented composite material.
5. The barrier of claim 1 wherein the body is substantially spherical.
6. The barrier of claim 1 wherein the projection extends from the body in one direction.
7. The barrier of claim 1 wherein the projection extends from the body in a plurality of directions.
8. The barrier of claim 1 wherein the projection comprises a solid rod.
9. The barrier of claim 1 wherein the projection is porous.
10. The barrier of claim 1 wherein the projection is comprised of a material selected from the group consisting of plastics, wood, composites, metals, substances soluble in water, substances soluble in cement, substances soluble in drilling fluids, and combinations of the foregoing.
11. The barrier of claim 1 wherein the projection comprises an extension.
12. The barrier of claim 1 wherein the projection is integrally formed with the body.
13. The barrier of claim 1 wherein the projection is perforated.
14. The barrier of claim 1 wherein the body has a diameter of about 0.75 inches to about 4 inches.
15. The barrier of claim 1 wherein the body has a density of about 62 pounds/ft3 to about 500 pounds/ft3.
16. The barrier of claim 1 wherein the projection comprises a length, the body comprises a length and the subterranean formation comprises a well having an inner diameter, and wherein the length of the projection combined with the length of the body is greater than the inner diameter of the well.
17. The barrier of claim 1 wherein the body comprises bismaleimide.
18. The barrier of claim 1 wherein the projection has a density of about 8 pounds/ft3 to about 500 pounds/ft3.
19. The barrier of claim 1 further comprising a magnet.
20. A system for substantially sealing a zone in a subterranean formation, the system comprising:
- a barrier, wherein the barrier comprises a body and a projection connectable with the body.
21. The barrier of claim 20 wherein the body comprises a laminated composite material.
22. The barrier of claim 20 where in the body comprises a randomly oriented composite material.
23. The barrier of claim 20 wherein the body is substantially spherical.
24. The barrier of claim 20 wherein the projection extends from the body in one direction.
25. The barrier of claim 20 wherein the projection extends from the body in a plurality of directions.
26. The barrier of claim 20 wherein the projection comprises a solid rod.
27. The barrier of claim 20 wherein the projection is porous.
28. The barrier of claim 20 wherein the projection is comprised of a material selected from the group consisting of plastics, wood, composites, metals, substances soluble in water, substances soluble in cement, substances soluble in drilling fluids, and combinations of the foregoing.
29. The barrier of claim 20 wherein the projection comprises an extension.
30. The barrier of claim 20 wherein the projection is integrally formed with the body.
31. The barrier of claim 20 wherein the projection is perforated.
32. The barrier of claim 20 wherein the body has a diameter of about 0.75 inches to about 4 inches.
33. The barrier of claim 20 wherein the body has a density of about 62 pounds/ft3 to about 500 pounds/ft3.
34. The barrier of claim 20 wherein the projection comprises a length, the body comprises a length and the subterranean formation comprises a well having an inner diameter, and wherein the length of the projection combined with the length of the body is greater than the inner diameter of the well.
35. The barrier of claim 20 wherein the body comprises bismaleimide.
36. The barrier of claim 20 wherein the projection has a density of about 8 pounds/ft3 to about 500 pounds/ft3.
37. A method of substantially sealing a zone in a subterranean formation, the subterranean formation comprising at least one seat, the method comprising the steps of:
- orienting a barrier comprising a body and a projection connectable with the body so that the barrier is substantially sealingly receivable in the seat.
38. The method of claim 37 further comprising the steps of removing the barrier from the subterranean formation and severing the projection from the body to facilitate removal of the barrier from the subterranean formation.
39. The method of claim 37 wherein the subterranean formation has a top side, the method further comprising the step of orienting the barrier with the projection pointing generally toward the top side of the formation.
40. The method of claim 37 wherein the subterranean formation has an under side, the method further comprising the step of orienting the barrier with the projection pointing generally toward the under side of the formation.
41. The method of claim 37 wherein the projection comprises a length, the body comprises a diameter and the subterranean formation comprises a diameter, and wherein the length of the projection combined with the length of the body is greater than the diameter of the subterranean formation.
42. The method of claim 37 further comprising the step of dissolving the projection prior to removing the barrier from the subterranean formation.
43. A method of substantially sealing a zone in a subterranean formation, the subterranean formation comprising at least one seat and a magnet associated with the seat, the method comprising the steps of:
- orienting a barrier comprising a body and a magnet so that the barrier is substantially sealingly receivable in the seat.
44. The method of claim 43 further comprising the steps of removing the barrier from the subterranean formation and severing the projection from the body to facilitate removal of the barrier from the subterranean formation.
45. The method of claim 43 wherein the subterranean formation has a top side, the method further comprising the step of orienting the barrier with the projection pointing generally toward the top side of the formation.
46. The method of claim 43 wherein the subterranean formation has an under side, the method further comprising the step of orienting the barrier with the projection pointing generally toward the under side of the formation.
47. The method of claim 43 wherein the projection comprises a length, the body comprises a diameter and the subterranean formation comprises a diameter, and wherein the length of the projection combined with the length of the body is greater than the inner diameter of the well.
48. A barrier for substantially sealing a zone in a subterranean formation, the barrier comprising:
- a body; and
- a magnet connectable with the body.
49. The barrier of claim 48 wherein the body is comprised of a material that is selected from the group consisting of fiberglass, carbon, polymers, thermoplastic resins, thermoset resins, metals, cloth, composites, and combinations of any of the foregoing.
50. The barrier of claim 48 wherein the body comprises a laminated composite material.
51. The barrier of claim 48 where in the body comprises a randomly oriented composite material.
52. The barrier of claim 48 wherein the body is substantially spherical.
53. The barrier of claim 48 wherein the projection is comprised of a material selected from the group consisting of plastics, wood, composites, metals, substances soluble in water, substances soluble in cement, substances soluble in drilling fluids, and combinations of the foregoing.
54. The barrier of claim 48 wherein the body has a diameter of about 0.75 inches to about 4 inches.
55. The barrier of claim 48 wherein the body has a density of about 62 pounds/ft3 to about 500 pounds/ft3.
56. The barrier of claim 1 wherein the projection has a density of about 8 pounds/ft3 to about 500 pounds/ft3.
57. A system for substantially sealing a zone in a subterranean formation, the system comprising:
- a body; and
- a magnet connectable with the body.
58. The barrier of claim 57 wherein the body is comprised of a material that is selected from the group consisting of fiberglass, carbon, polymers, thermoplastic resins, thermoset resins, metals, cloth, composites, and combinations of any of the foregoing.
59. The barrier of claim 57 wherein the body comprises a laminated composite material.
60. The barrier of claim 57 where in the body comprises a randomly oriented composite material.
61. The barrier of claim 57 wherein the body is substantially spherical.
62. The barrier of claim 57 wherein the projection is comprised of a material selected from the group consisting of plastics, wood, composites, metals, substances soluble in water, substances soluble in cement, substances soluble in drilling fluids, and combinations of the foregoing.
63. The barrier of claim 57 wherein the body has a diameter of about 0.75 inches to about 4 inches.
64. The barrier of claim 57 wherein the body has a density of about 62 pounds/ft3 to about 500 pounds/ft3.
66. The barrier of claim 57 wherein the projection has a density of about 8 pounds/ft3 to about 500 pounds/ft3.
67. A composite fracturing ball comprising bismaleimide resin.
Type: Application
Filed: Jan 9, 2014
Publication Date: Jul 9, 2015
Applicants: Quantum Composites, Inc. (Bay City, MI), Premix, Inc. (North Kingsville, OH)
Inventors: Michael Dale Kiesel (Bay City, MI), Matthew Louis Kaczmarczyk (Bay City, MI), Marc Imbrogno (Mentor, OH)
Application Number: 14/151,402