GB2528054A - Casing removal with energetic materials - Google Patents

Casing removal with energetic materials Download PDF

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Publication number
GB2528054A
GB2528054A GB1412062.0A GB201412062A GB2528054A GB 2528054 A GB2528054 A GB 2528054A GB 201412062 A GB201412062 A GB 201412062A GB 2528054 A GB2528054 A GB 2528054A
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GB
United Kingdom
Prior art keywords
fuel
casing
nozzle
flame
oxidant
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1412062.0A
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GB201412062D0 (en
Inventor
Gjermund Grimsbo
Marcus Fathi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Equinor Energy AS
Original Assignee
Statoil Petroleum ASA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Statoil Petroleum ASA filed Critical Statoil Petroleum ASA
Priority to GB1412062.0A priority Critical patent/GB2528054A/en
Publication of GB201412062D0 publication Critical patent/GB201412062D0/en
Publication of GB2528054A publication Critical patent/GB2528054A/en
Withdrawn legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B29/00Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E21B29/02Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground by explosives or by thermal or chemical means

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  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Geology (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Solid Fuels And Fuel-Associated Substances (AREA)

Abstract

A method of removing a section of casing 4 within a well involves placing a cutting tool downhole, the tool comprising a fuel source and at least one burn nozzle 1 having a tip 3 coupled to the fuel source, igniting the fuel to cause a flame to be emitted from the burn nozzle, and moving the cutting tool along the well in order to heat and thereby remove the section of casing.

Description

Casing removal with energetic materials
Technical field
This invention relates to well construction, plugging and abandonment of wells and more particularly, but not restricted to, removing a portion of a casing in a well.
Background
A well typically includes a casing which provides a pathway for tools and fluids. The casing may be made out of steel. During drilling and well operation, including plug and abandonment of a well, removal of a portion of the casing may be required. For example, the formation or an outer casing can be exposed after removal of the steel casing along part of the length of the casing and a plug can then be placed in the portion where the steel casing has been removed. The removal of the steel casing needs to be complete for a plug to be formed efficiently and for the avoidance of leaks.
An existing method for removing part of a casing is milling, whereby a drilling rig is used. A drawback of that method is that it is time consuming and inefficient. Also, the waste material from the milling operation, also known as swarf, needs to be transported to the surface through a blow-out preventer, which may damage the blow-out preventer or cause other safety problems.
Statement of invention
According to the first aspect of the invention, there is provided a method of removing a section of casing within a well, the method comprising: placing a cutting tool downhole, the tool comprising a fuel source and at least one burn nozzle coupled to the fuel source; igniting the fuel to cause a flame to be emitted from the at least one burn nozzle; and moving the cutting tool along the well in order to heat and thereby remove said section of casing.
The fuel source may comprise at least one fuel tank. The cutting too may further comprise an oxidant reservoir and a means for emitting the oxidant through the nozzle together with the flame, and the method may further comprise applying a combination of the flame and the oxidant to the secton of the casing at high velocity, such as the speed of sound.
The flame may be generated by burning a fuel in a combustion chamber. The oxidant may comprise one of hydrogen peroxide, nitrous oxide, carbon monoxide and carbon dioxide and the fuel and the oxidant may both be provided by solid fuel. The method may also comprise oxidising the portion of the steel casing before the steel reaches a melting temperature.
According to a second aspect of the invention, there is provided a device for removing a section of a steel casing within a well, the device comprising: a fuel source and at least one burn nozzle; and a combustion chamber coupled to the fuel source and the burn nozzle.
The at least one burn nozzle may comprise a plurality of nozzles distributed symmetrically around an axis of the device which in use coincides with the longitudinal axis of the casing. The nozzle may be a ring shaped nozzle.
The device may be arranged to generate a flame using any one of: a liquid fuel in combination with a liquid oxidiser; a sold fuel; a liquid oxidiser in combination with a solid fuel.
Drawings Some embodiments of the invention will now be described by way of example only and with reference to the accompanying figures, in which: Figure 1 illustrates a nozzle; Figure 2 illustrates a nozzle in a casing; FigureS illustrates a tool with multiple nozzles; Figure 4 illustrates a ring shaped nozzle; Figures illustrates a heat distribution of a flame; and Figure 6 is a flow diagram of a method of removing a section of a casing.
Specific description
The inventors have appreciated that a downhole portion of casing steel can be removed by applying very high levels of heat to the casing, for example using a flame from burning fuel, possibly together with an oxidant. The heat and oxidant may be provided from two different sources, or from the same source. In addition! a large heat flux may be applied to the steel casing, for example by a large velocity of the flame.
When the velocity of the gasses in the flame is high, thereby providing a high heat flux onto the steel, high shear forces are applied to the steel wall. As a result of the shear forces, the steel will turn into very small droplets when it melts and be transported away from the wall together with the flow of gas away from the flame. An example of a high velocity suitable to achieve this effect is a sonic velocity, but a gas velocity below the speed of sound may be sufficient.
Most metals are unstable in contact with oxygen and it is only reaction kinetics and oxygen availability that prevents them from fast oxidation in normal use. For example, magnesium is known to be able to combust spontaneously. Iron can also ignite, but requires high temperatures to do so. Steel is an alloy of iron with carbon. If the flame applied to the steel casing is rich in oxidants, the steel will oxidize into iron oxides before the melting point is reached. The iron oxide will move away from the metal wall as small particles or dust. The oxidation of steel, in particular iron in the steel material, is exothermic, whereby the reaction releases heat from the system, and the required heat input will therefore be less than the input required for heating the steel up to its melting point.
Examples of fuels that can be used are conventional carbon based fuels in combination with suitable oxidants, such as hydrogen peroxide or nitrous oxide. At high temperatures, carbon monoxide and carbon dioxide could also be used as an oxidant.
Solid state rocket propellants may also be used. Excess oxygen in a flame is used to allow the iron to oxidise and be mobilized before the melting point is reached. The mobilized metal in the form of droplets or iron oxide particles is very small compared with milling swarf, and can be circulated out with the fluid in the well. Combustion products, such as carbon dioxide, water and possibly nitrogen will have to be dealt with on surface.
Some specific examples of heat sources are now discussed which exploit chemical energy which is transferred into hot gasses moving at an extremely high velocity, possibly similar to the speed of sound. The inventors have appreciated that some technology from rocket engines and rocket engine fuels could be used in the removal of well casings. Three examples of rocket engine fuel are considered: a liquid fuel source, a solid propellant or a hybrid of these.
A liquid fuel rocket energy source uses a fuel and an oxidizer, both in liquid form. The liquid rocket energy source allows for long burn times, only limited by the size of the propellant tanks of the rocket and the capability of the system to cool itself. It can be regulated, stopped and restarted if desired. A liquid rocket engine is complex as both the oxidizer and the fuel have to be pumped to the reaction chamber at the right mixture ratio, while complexity increases even more if the fuel is to be used to cool the hot components in order to obtain the long burn times. Continuous burn times in excess of 10 minutes are possible with efficient cooling and these engines can be re-used for burn times of several hours in total. The inventors have apprecated that the same principles can be used downhole for the removal of casing steel.
A solid fuel rocket energy source consists of a chemical compound generating a large amount of energy which is released in a very short time by extremely fast oxidizing reactions within the chemical compound itself. The reaction cannot be stopped after it has started and the motor will burn until all the propellant is consumed. All the propellant is stored in the reaction chamber. The propellant has to be treated like an explosive material. It is the simplest rocket engine possible, and also the most effective based on volume. The limited amount of propellant, the lack of cooling and erosion of parts exposed to the hot gasses limit the burn time to 1 to 3 minutes. The application of solid state rocket fuel for removing casing steel has the benefit of avoiding the need of a complicated tool.
A hybrid rocket fuel source is a variant of a solid rocket fuel source in which the oxidizer is removed again from the fuel and supplied in liquid form. This enables the hybrid rocket fuel source to be regulated and stopped and restarted if desred. The fuel itself is inert and stored in the (smaller) reaction chamber. The oxidizer can be pressure fed avoiding expensive pumps. The burn time will be limited by the fuel present in the reaction chamber and the size of the oxidizer tank. The oxidizer/fuel ratio is about 6 to 7, which makes it possible to obtain longer burn times when compared with a solid rocket fuel source. Based on the same size of combustion chamber, a hybrid rocket engine can burn 6 to 7 times longer than a solid fuel rocket engine. However, the lack of cooling and erosion of parts exposed to the hot gasses will still limit the burn time to minutes instead of hours.
All three rocket fuel types can provide the temperatures and gas velocities which are needed for rapidly removing casing steel. The embodiments discussed below make use of some of the concepts of rocket engines.
The tool used for providing the flame does not require a top drive to be operated, so it can be deployed from a vessel, as long as the gases produced in the hole can be handled, e.g. vented, in a safe way. The tool can therefore avoid the use of rig time for removal of steel.
A combustion chamber may be used for burning the fuel. In a combuston chamber, the fuels ignite and the flow out of the chamber is restricted by the diameter of the nozzle. Pressure will build up until equilibrium is reached between reaction kinetics and the flow out of the nozzle. The concept of using a combustion chamber is different from weld-cutting, where reactants are mixed and ignited in open air". The design of a combustion chamber requires more knowledge and engineering than the design of conventional weld-flame tools. Benefits of using a combustion chamber is having a controlled combustion and well defined parameters in the flame and nozzle, together with higher velocities of the flow out of the nozzle.
The tool supplying the flame can be moved around the well and upwards along the steel casing of the well for removing a portion of the casing steel. The flame can be led through a circular nozzle towards the steel or by a full cone flame that heats the entire circumference of the casing at the same time.
Figures 1 and 2 illustrate a single nozzle 1 which is at one end attached to the fuel source 2 and which terminates at the other end at a tip 3 which has an angle such that the flame is directed towards the casing 4. Figure 3 illustrates a fuel source 2 which terminates in three individual nozzles 5 which are directed towards the casing 4. A single nozzle or multiple nozzles may be attached to the end of a rocket fuel source segment which acts as a fuel source. The whole fuel source may be lowered into the well casing to the desired depth. The fuel source can be ignited and the nozzle can be rotated and moved upwards at the appropriate speed of removal. The nozzle(s) will describe a helical path such that a portion of the casing around the entire circumference of the casing is removed. The devices illustrated in Figures 1 * 2 and 3 allow for the controlled removal of a portion of the casing.
Figure 4 illustrates a fuel source 2, such as a rocket fuel source segment, which terminates in a ring shaped nozzle 6 for directing a flame simultaneously to a circular portion of the casing 4. The ring shaped nozzle may be provided at the bottom of a rocket fuel source segment. The whole fuel source may be lowered into the well casing to the desired depth. The fuel source will be ignited and moved upwards at the appropriate speed. A larger area will be heated by the flame at a given time when compared to the single or multiple nozzles of Figures 1 to 3. If larger areas are targeted simultaneously, that might be the more effective, but the flow of the flame through a ring shaped nozzle may be more difficult to control and the erosion of the ring shaped nozzle may also be more difficult to control.
The cutting nozzle size has a significant influence on the cutting speed. A smaller cutting nozzle size will concentrate the energy more, but a smaller rocket nozzle will erode much faster when compared to a larger one. An example of single nozzle size is a diameter of 12mm, in a nozzle as Ilustrated in Figures 1 and 2. This size is compromise between an acceptable erosion of the nozzle on one hand and a concentrated jet of energy to promote cutting on the other and. The nozzle will not have a divergent section behind the nozzle throat, but terminate is a narrow tip 3 as shown n Fig. 1. This is because a divergent section of the sonic nozzle would result in a reduction of the pressure and the temperature of the jet to promote velocity of a rocket. For the present application of removing casing steel, a highest possible temperature is the most desirable property of the rocket fuel source exhaust jet. The velocity will already be at the local speed of sound based on the fact that the nozzle is sonic.
By way of example, the total energy content of a solid rocket propellant is typically 5.4 MJ/kg. A nozzle with a diameter of 12mm can be used to generate a circular flame with a diameter of 12mm. The flame strikes the casing at an angle of 45 degrees. The heat release is 14.5 MJ/s and the combustion rate is 2.7 kg/s of fuel. The total amount of steel which can be heated adiabatically and completely melted using 1kg of solid propellant is 4.43 kg. The time for the flame to penetrate the wall is less than 4 seconds and the cutting velocity is between 7 to 14mm per second. Fig. 5 illustrates a calculation of the heat distribution of a flame generated by burning rocket fuel. The heat has a narrow distribution with dimensions which are similar to the dimensions of the nozzle.
Figure 6 is a flow diagram illustrating a method as herein described, showing the steps of providing a cutting tool within a casing (Si), igniting fuel to emit a flame from a burn nozzle (52) and moving the cutting tool to a further location of the casing (53).
Although the invention has been described in terms of preferred embodiments as set forth above, it should be understood that these embodiments are illustrative only and that the claims are not limited to those embodiments. Those skilled in the art will be able to make modifications and alternatives in view of the disclosure which are contemplated as falling within the scope of the appended claims. Each feature disclosed or illustrated in the present specification may be incorporated in the invention, whether alone or in any appropriate combination with any other feature disclosed or illustrated herein.

Claims (12)

  1. CLAIMS: 1. A method of removing a section of casing within a well, the method comprising: placing a cutting tool downhole, the tool comprising a fuel source and at least one burn nozzle coupled to the fuel source; igniting the fuel to cause a flame to be emitted from the at least one burn nozzle; and moving the cutting tool along the well in order to heat and thereby remove said section of casing.
  2. 2. A method according to claim 1, wherein said fuel source comprises at least one fuel tank.
  3. 3. The method of claim 1, wherein the cutting tool further comprises an oxidant reservoir and a means for emitting the oxidant through the nozzle together with the flame, and wherein the method further comprises applying a combination of the flame and the oxidant to the section of the casing at high velocity.
  4. 4. The method according to any one of the preceding claims, wherein the flame is generated by burning a fuel in a combustion chamber.
  5. 5. The method according to claim 3 or 4, wherein the oxidant comprises one of hydrogen peroxide, nitrous oxide, carbon monoxide and carbon dioxide.
  6. 6. The method according to any one of claims 3 to 5, wherein the fuel and the oxidant are both provided by solid fuel.
  7. 7. The method according to claim 3, wherein the high velocity is substantially the speed of sound.
  8. 8. The method according to any one of the preceding claims, further comprising oxidising the portion of the steel casing before the steel reaches a melting temperature.
  9. 9. A device for removing a section of a steel casing within a well, the device comprising: a fuel source and at least one burn nozzle; and a combustion chamber coupled to the fuel source and the burn nozzle.
  10. 10. The device of claim 9, wherein the at least one burn nozzle comprises a plurality of nozzles distributed symmetrically around an axis of the device which in use coincides with the longitudinal axis of the casing.
  11. 11. The device of claim 9, wherein the at least one nozzle is a ring shaped nozzle.
  12. 12. The device of any one of claims 9 to 11, wherein the device is arranged to generate a flame using any one of: a liquid fuel in combination with a liquid oxidiser; a solid fuel; a liquid oxidiser in combination with a solid fuel.
GB1412062.0A 2014-07-07 2014-07-07 Casing removal with energetic materials Withdrawn GB2528054A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1412062.0A GB2528054A (en) 2014-07-07 2014-07-07 Casing removal with energetic materials

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1412062.0A GB2528054A (en) 2014-07-07 2014-07-07 Casing removal with energetic materials

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GB201412062D0 GB201412062D0 (en) 2014-08-20
GB2528054A true GB2528054A (en) 2016-01-13

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018138479A1 (en) * 2017-01-25 2018-08-02 Clearwell Technology Ltd Thermal apparatus and associated methods
WO2020254659A1 (en) * 2019-06-19 2020-12-24 Spex Oil & Gas Limited Downhole tool with fuel system

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2084713A (en) * 1980-10-03 1982-04-15 Jet Research Center Method apparatus and pyrotechnic compositions for severing conduits
US4446920A (en) * 1983-01-13 1984-05-08 Air Products And Chemicals, Inc. Method and apparatus for perforating or cutting with a solid fueled gas mixture
GB2169940A (en) * 1985-01-07 1986-07-23 C Robertson Michael Pipe cutting apparatus
GB2198772A (en) * 1986-10-17 1988-06-22 Decom Co Method and apparatus for cutting piling of offshore platforms
US5435394A (en) * 1994-06-01 1995-07-25 Mcr Corporation Anchor system for pipe cutting apparatus
GB2346633A (en) * 1999-01-15 2000-08-16 Baker Hughes Inc Window forming by flame cutting
EP1262268A1 (en) * 2001-06-01 2002-12-04 Ceramic & Materials processing, Inc. High-speed chemical drill
WO2007049026A1 (en) * 2005-10-24 2007-05-03 Geoprober Drilling Limited Cutting device and method
WO2010019252A1 (en) * 2008-08-13 2010-02-18 Robertson Michael C Consumable downhole tool

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2084713A (en) * 1980-10-03 1982-04-15 Jet Research Center Method apparatus and pyrotechnic compositions for severing conduits
US4446920A (en) * 1983-01-13 1984-05-08 Air Products And Chemicals, Inc. Method and apparatus for perforating or cutting with a solid fueled gas mixture
GB2169940A (en) * 1985-01-07 1986-07-23 C Robertson Michael Pipe cutting apparatus
GB2198772A (en) * 1986-10-17 1988-06-22 Decom Co Method and apparatus for cutting piling of offshore platforms
US5435394A (en) * 1994-06-01 1995-07-25 Mcr Corporation Anchor system for pipe cutting apparatus
GB2346633A (en) * 1999-01-15 2000-08-16 Baker Hughes Inc Window forming by flame cutting
EP1262268A1 (en) * 2001-06-01 2002-12-04 Ceramic & Materials processing, Inc. High-speed chemical drill
WO2007049026A1 (en) * 2005-10-24 2007-05-03 Geoprober Drilling Limited Cutting device and method
WO2010019252A1 (en) * 2008-08-13 2010-02-18 Robertson Michael C Consumable downhole tool

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018138479A1 (en) * 2017-01-25 2018-08-02 Clearwell Technology Ltd Thermal apparatus and associated methods
US11299949B2 (en) 2017-01-25 2022-04-12 Clearwell Technology Ltd Thermal apparatus and associated methods
WO2020254659A1 (en) * 2019-06-19 2020-12-24 Spex Oil & Gas Limited Downhole tool with fuel system

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