BIG HOLE CHARGE FOR PLUG AND ABANDONMENT
A liner for a shaped charge. The liner, when the associated shaped charge is detonated, does not create a plug, carrot, or residue in the created perforation tunnel. The liner is made of a material that includes one or more of a bulk metallic glass complex (BMGC) or a high entropy alloy (HEA). The liner can include super-hard materials. The liner can be produced using one or more of a severe plastic deformation process, a cold isostatic pressing process, or a spark plasma sinter process.
Latest Damorphe Patents:
This application claims priority to U.S. Provisional Patent Application No. 63/208,610 entitled BIG HOLE CHARGE FOR PLUG AND ABANDONMENT filed Jun. 9, 2022 which is incorporated herein by reference in its entirety.
BACKGROUNDShaped charges are commonly used in perforation and fracturing operations to create holes in a formation that facilitates hydrocarbon production. Many shaped charges are generally cone-shaped and have an interior concave region that faces outward toward the formation to focus the blast from the shaped charge outward. Shaped charges have evolved to include a liner on the concave region to protect the shaped charge during transport and run-in-hole.
SUMMARYEmbodiments of the present disclosure are directed to an apparatus including a case having an interior volume, an explosive material in the interior volume of the case, and a liner in the interior volume. The explosive material is between the liner and the case. The liner is made from a powder complex comprising a powdered copper-lead mixture and a powdered additive complex comprising at least one of a bulk metallic glass composite (BMGC) or a high entropy alloy (HEA) material.
Further embodiments of the present disclosure are directed to a liner for a shaped charge. The liner includes a powder complex including at least one of a bulk metallic glass complex (BMGC) and a high entropy alloy (HEA). The liner, when an associated shaped charge is detonated, dissolves into a hydrocarbon-permeable material.
Still further embodiments of the present disclosure are directed to a liner for a shaped charge having a gradient material formed by blending two or more powdered materials and at least one organic material, each having a dissimilar specific gravity. A force is applied to the gradient material causing the powdered materials and the organic material to align according to their specific gravities.
Other embodiments of the present disclosure are directed to a method of manufacturing a liner for a shaped charge including forming a powder complex of material comprising at least one of bulk metallic glass complex (BMGC) or high entropy alloy (HEA), and processing the powder complex such that detonation of an associated shaped charge causes the liner to jet, thereby penetrating a casing and a formation to form a perforation tunnel. Residue of the liner after jetting in the perforation tunnel reacts and dissolves in organic production fluids.
Liners for shaped explosive charges in perforation tools may collapse and develop a high-speed jet creating tunnels in a subterranean formation during a perforation event. Such liners may be referred to as shaped charge liners. The present disclosure is directed to liners for shaped charges that, when the charge is detonated, does not leave a skin, carrot, or residue in the tunnel, thereby improving flowback characteristics of the formation. The liners of the present disclosure in some embodiments are made from a Bulk Metallic Glass Composite (BMGC) material and a High Entropy Alloy (HEA) material. During the detonation event, the materials react via a shock-induced entropy change to create a BMGC or HEA that preferably segregate to create high-angle domain boundaries or interfaces of the jetted liner material. As the jet progresses into the formation creating a perforation tunnel, segregated BMGC/HEA complex instantly reacts with formation fluids generating hydrogen, disintegrating the jet into a sputtered deposit.
In some embodiments the liner 156 is made of a combination of copper, lead, and tungsten. The materials of the liner 156, in this case copper, lead, and tungsten, are combined in powder form. In some embodiments the material is made of solid copper or an alloyed copper liner. In some embodiments the liner also includes an additional solid metal liner stemming from an electrochemically active alloy such as Zinc or a Zinc alloy which is processed onto the copper alloy liner by mechanical means. The use of a powder compact negates formation of plug or carrot at the end of a perforation tunnel or a skin on interior surfaces of the perforation tunnel. Use of the powder compact maintains the conductivity of the material left behind in the perforation tunnel which enables the residue to dissolve and therefore not obstruct production from the perforation tunnel.
In some embodiments the powder complex is made of a copper or copper alloy. The powder complex can include a copper-lead mixture. The powder complex can also include be a superplastic alloy such as a Zn-22 wt. % Al eutectoid material. In some embodiments a multi-phase High Entropy Alloy (HEA) with glass forming abilities area added to the blend to promote formation of amorphous intergranular fringes (AIF, a.k.a. complexions), engineered to react at tailored degradation rates with aqueous or organic phases. These materials can disintegrate on a timed exposure to the environment. In other embodiments super-hard materials such as sintered carbides or nitrides can be used. Examples of super-hard materials are SiC, Si3N4, B4C, BN, AL2O3, Zr and Zr—Al2O3, Al2O3—Zr, and B4C—SiC. These materials have ultra-refined and classified particle size distribution. On such example is F1000 or F1500 that can be added to the blend. These materials are selectively deposited on the perforation tunnel to prevent collapse of fine conductive channels while creating a porous permeable layer, rather than an impermeable skin that is formed using conventional shaped charge liners. This allows improved hydrocarbon flowback and increased conductivity of the perforation pathway. In some embodiments the powder material consists of refractory and other metal powders such as W, Mo, or Zr to add weight and elasticity to the formed jet, thus promoting a deeper penetration.
In some embodiments the multi-phase powders with a glass forming ability are added to the blend to promote formation of amorphous intergranular films (AIF) and/or complexions that are engineered to react at tailored degradation rates with aqueous or organic phases that disintegrated on a timed exposure. This increases system enthalpy, flares the jet, which results in a larger hole even when shot from a smaller diameter gun such as a 3⅛ inch OD gun.
Further examples of refractory alloy powders may be a combination of ITAR (International Traffic in Arms Regulations) registered alloys such as Titanium Zirconium, Molybdenum (TZM), Lanthanated Molybdenum (MoLa), Tungsten heavy alloy (W), or other metals and alloyed forms of the elements Niobium, Tantalum, Rhenium, Hafnium, Zirconium, and Iridium.
In some embodiments the powders are processed via severe plastic deformation (SPD) to produce nano-crystalline and ultrafine grains. The ultrafine grains in the SPD processed powders manifest into “high strain rate super plasticity” of the formed jet at temperatures during detonation.
In some embodiments a gradient material liner can be produced consisting of dissimilar metals or alloys that can be produced by repeated strikes in a liner press. A polymer or a wax can be selectively introduced between gradients to increase gradient material reactivity which results in a big hole even when shot from a relatively small diameter gun such as a 3⅛ inch OD gun.
In some embodiments the shaped charge liners can be made from a powder compact which is pressed into shape using a hydraulic press or other similar pressure-applying mechanism. The high pressure causes the powders to solidify into the desired shape. A coating such as a GLYPTAL™ can be applied to the liner 156, which can then be pressed onto the shaped charge against the explosive material 154 and into the case 152. The shaped charge 150 and liner 156 are now ready for deployment.
The metal powders have a tailored particle size distribution that maximizes the tap density of the blend. When the shaped charge 150 is detonated, behind the liner a liner-metal jet is formed which punctures the gun, the casing, and finally penetrates the formation, thus creating a perforation tunnel. During the detonation, the metal powders react via a shock induced entropy-change (or propagating pressure wave) to create a bulk metallic glass (BMG). In other embodiments, a high entropy alloy (HEA) is used and it preferentially segregates to the high angle boundaries or interfaces of the liner material deposited on the crushed zone, coating the perforation tunnel. In some embodiments the BMG materials are used with the HEA materials. In other embodiments the BMG materials are used without the HEA materials, and in other embodiments the HEA materials are used without the BMG materials.
In any of these embodiments, BMG, HEA, or BMG+HEA, the materials segregated at the high angle boundaries or the domain interfaces of the liner-metal skin on the perforating tunnel reacts with formation fluids and is selectively etched. This results in the metal coating and slug at the end of the perforation tunnel disintegrating into minute particulates that are easily removed via flowback. The result is a clear pathway for hydrocarbons to flow from the formation.
In some embodiments the powder compact can be manufactured using additive manufacturing. The shaped charge liners can also be made from a powder compact using cold isostatic pressing (CIP) of the powder compact or a spark plasma sinter (SPS) method. In other embodiments the shaped charge liners can also be made using a hot forge in a closed die. In other embodiments the charge liner is designed from a powder compact using additive manufacturing. In other embodiments the gradient materials have weaved-in tracers and can be produced via cold isostatic pressing or spart plasma sintering. In other embodiments the liner can be forged and can be re-stricken to reduce porosity and heal material, to thus abet super-plasticity and elasticity of the jet produced by detonation of the shaped charge.
The result of the detonation event shown here results in a perforation tunnel that extends deep into the formation. Due to the material makeup of the liner 156, the liner material 156 is either dissolved during the detonation event, or it remains in the perforation tunnel but is rendered highly reactive to formation fluids and will break up into very small particles in minutes. These particles are easily flowed back due to the natural pressure coming from the formation and will not impede hydrocarbon production. Compare to the conventional design and materials which leave a substantial plug that does not dissolve and renders the perforation much less able to produce hydrocarbons.
In some embodiments the liners for the shaped charges disclosed herein can include a gradient material that is formed by blending two or more powdered materials having dissimilar specific gravities. An organic material, such as a polymer or a wax, can be blended with the powdered materials. The combination of these materials can be subject to a force such as a centrifugal force that causes the materials to align according to specific gravity. At this point a further processing step can be performed to solidify or otherwise work the materials. Such further processing steps include cold isostatic pressing or severe plastic deformation or other such processes. In the embodiments of the present disclosure, a cone-shaped liner can be so produced using the symmetry of the cone shape for the liner to construct the gradient material.
The foregoing disclosure hereby enables a person of ordinary skill in the art to make and use the disclosed systems without undue experimentation. Certain examples are given to for purposes of explanation and are not given in a limiting manner.
Claims
1. An apparatus, comprising:
- a case having an interior volume;
- an explosive material in the interior volume of the case; and
- a liner in the interior volume, wherein the explosive material is between the liner and the case, wherein the liner is made from a powder complex comprising: a powdered copper-lead mixture; and
- a powdered additive complex comprising at least one of a bulk metallic glass composite (BMGC) or a high entropy alloy (HEA) material.
2. The apparatus of claim 1 wherein the powdered additive complex comprises up to 51% by weight of the powder complex.
3. The apparatus of claim 1 wherein the liner is configured to react to detonation of the explosive material with a shock-induced entropy-change that creates amorphous intergranular fringes (AIFs), wherein the AIFs are sputtered along a perforation tunnel caused by detonation of the explosive material, and wherein the AIF is reactive to stimulation and formation fluids and removed on contact with the stimulation and formation fluids.
4. The apparatus of claim 2 wherein the stimulation and formation fluids comprise aqueous fluids and acids.
5. The apparatus of claim 1 wherein the powdered additive complex comprises a mix of BMGC and HEA materials.
6. The apparatus of claim 5 wherein the powdered additive complex comprises up to 25% of BMGC.
7. The apparatus of claim 5 wherein the powdered additive complex comprises up to 25% of HEA.
8. The apparatus of claim 1 wherein the powdered additive complex is a super plastic material.
9. The apparatus of claim 8 wherein the super plastic material is a Zn-22 wt % Al powder.
10. The apparatus of claim 8 wherein the powdered additive complex is a eutectoid.
11. The apparatus of claim 1 wherein the HEA materials have a glass forming ability.
12. The apparatus of claim 1 wherein the HEA material promotes formation of amorphous intergranular films that are engineered to react at tailored degradation rates with aqueous or organic phases disintegrating on a timed exposure.
13. The apparatus of claim 1 wherein the liner includes super-hard materials with an ultra-refined particle size distribution that are selectively deposited on a perforation tunnel caused by detonating the explosive material, wherein the ultra-refined particle size distribution prevents collapse of fine conductive channels and to create a layer on an interior surface of the perforation tunnel that is porous and permeable to hydrocarbons.
14. The apparatus of claim 13 wherein the super-hard materials include one or more of SiC, Si3N4, B4C, BN, AL2O3, Zr and Zr—Al2O3, Al2O3—Zr, B4C—SiC.
15. The apparatus of claim 13 wherein the particle size of the super-hard materials is F1000-F1500.
16. The apparatus of claim 1 wherein the powder complex further comprises one or more refractory metals.
17. The apparatus of claim 16 wherein the refractory metals comprise at least one of W, Mo, Zr, TZM (Titanium, Zirconium, Molybdenum), MoLa (Lanthanated Molybdenum), W (Tungsten heavy alloy) or other metals and alloyed forms of the elements:
- Niobium, Tantalum, and Rhenium, Hafnium, Zirconium, and Iridium.
18. The apparatus of claim 1 wherein the liner is made from a powder material that is processed via severe plastic deformation (SPD) to produce nano-crystalline and ultrafine grains.
19. The apparatus of claim 18 wherein the SPD processed powders, during detonation of the explosive material, manifest high strain rate super plasticity.
20. A liner for a shaped charge, the liner comprising:
- a powder complex including at least one of a bulk metallic glass complex (BMGC) and a high entropy alloy (HEA), wherein the liner, when an associated shaped charge is detonated, dissolves into a hydrocarbon-permeable material.
21. The liner of claim 20 wherein the liner is a bulk metallic glass complex.
22. The liner of claim 20 wherein the liner is a high entropy alloy.
23. The liner of claim 20 wherein the liner, when an associated shaped charge is detonated, causes
24. The liner of claim 20 wherein the liner is a gradient material liner comprising dissimilar metals
25. The liner of claim 20 wherein the powder complex includes a super plastic material.
26. The liner of claim 25 wherein the super plastic material comprises Zn-22 wt. % Al material.
27. A liner for a shaped charge, comprising:
- a gradient material formed by blending two or more powdered materials and at least one organic material, each having a dissimilar specific gravity, wherein a force is applied to the gradient material causing the powdered materials and the organic material to align according to their specific gravities.
28. The liner of claim 27 wherein the gradient material undergoes a cold isostatic pressing (CIP) process.
29. The liner of claim 27 wherein the organic material comprises a polymer or a wax.
30. The liner of claim 27 wherein the force comprises a centrifugal force.
31. A method of manufacturing a liner for a shaped charge, the method comprising:
- forming a powder complex of material comprising at least one of bulk metallic glass complex (BMGC) or high entropy alloy (HEA); and
- processing the powder complex such that detonation of an associated shaped charge causes the liner to jet, thereby penetrating a casing and a formation to form a perforation tunnel, wherein residue of the liner after jetting in the perforation tunnel reacts and dissolves in organic production fluids.
32. The method of claim 31, further comprising processing the powder complex using cold isostatic pressing.
33. The method of claim 31, further comprising processing the powder complex using a spark plasma sinter process.
34. The method of claim 31, further comprising processing the powder complex using a severe plastic deformation process.
Type: Application
Filed: Jun 8, 2022
Publication Date: Apr 25, 2024
Applicant: Damorphe (Houston, TX)
Inventors: TIng Chen (Sugar Land, TX), Indranil Roy (Sugar Land, TX), Kamel Bennaceur (Paris), Hifzi Ardic (Houston, TX)
Application Number: 17/836,968