US20140332220A1

US20140332220A1 - Polyurethane activator-breaker fluid system

Info

Publication number: US20140332220A1
Application number: US13/892,785
Authority: US
Inventors: Ramon R. Garza; Anuradee Witthayapanyanon; Thomas A. Jones
Original assignee: Baker Hughes Inc
Current assignee: Baker Hughes Holdings LLC
Priority date: 2013-05-13
Filing date: 2013-05-13
Publication date: 2014-11-13

Abstract

A combined activator-breaker fluid system is effective in oil and gas field applications to essentially simultaneously activate or deploy a shape-memory material and at least partially remove a polymeric filter cake left by a drilling mud, all in one step or trip.

Description

TECHNICAL FIELD

The present invention relates to methods and compositions used in oil and gas wellbores for employing shape-memory materials and methods and compositions used in wellbores for removing polymer filter cakes and more particularly relates to methods and compositions for essentially simultaneously activating shape-memory materials and removing polymer filter cakes.

TECHNICAL BACKGROUND

Various methods of filtration, wellbore isolation, production control, wellbore lifecycle management, and wellbore construction are known in the art. The use of shaped memory materials in these applications have been disclosed for oil and gas exploitation. Shape Memory Materials are smart materials that have the ability to return from a deformed state (temporary shape) to their original (permanent) shape induced by an external stimulus or trigger (e.g. temperature change, contact with a fluid, etc.). In addition to temperature change, the shape memory effect of these materials may also be triggered by an electric or magnetic field, light or a change in pH. Shape-memory polymers (SMPs) cover a wide property range from stable to biodegradable, from soft to hard, and from elastic to rigid, depending on the structural units that constitute the SMP. SMPs include thermoplastic and thermoset (covalently cross-linked) polymeric materials. SMPs are known to be able to store multiple shapes in memory.
U.S. Pat. No. 7,318,481 assigned to Baker Hughes Incorporated disclosed a self-conforming expandable screen which comprises a thermosetting open cell shape-memory polymeric foam. The foam material composition is formulated to achieve the desired transition temperature slightly below the anticipated downhole temperature at the depth at which the assembly will be used. This causes the conforming foam to expand at the temperature found at the desired depth.
An apparatus and method for filling a defined space, such as an annulus around a production tubular within a wellbore, includes a compliant porous material as described in U.S. Pat. No. 7,828,055 assigned to Baker Hughes Incorporated. The compliant porous material can be compressed and maintained in a compressed state by incorporation of a deployment modifier which may be a water-soluble or oil-soluble adhesive or biopolymer, used as an impregnant, a coating, or a casing. The production tubular can be positioned at a desired location and the compliant porous material exposed to a deployment modifier neutralizing agent, which then dissolves or otherwise prevents the deployment modifier from continuing to inhibit the deployment. Thus, deployment can be delayed to an optimum time by controlling exposure of the deployment modifier to the deployment modifier neutralizing agent.
U.S. Pat. No. 8,353,346 assigned to Baker Hughes Incorporated describes that the actuation and control of the deployment of a polymeric memory-shape material on a wellbore device on a downhole tool may be accomplished by treating a compacted or compressed polymeric memory-shape material with a deployment fluid to lower its T_gand/or decrease its rigidity, thereby softening the polymeric shape-memory material at a given temperature and triggering its expansion or recovery at a lower temperature. Alternatively, the deployment of the compacted or compressed polymeric memory-shape material may be prevented or inhibited by shielding the material with an environment of a fluid that does not substantially lower its T_gdecrease its rigidity or both, and then subsequently contacting the material with a deployment fluid.
In a different aspect of oil and gas recovery (i.e. hydrocarbon drilling and production), polymeric filter cakes are a byproduct of typical well operations, such as hydraulic fracturing and subsequent drill operations. Polymer (or polymeric) filter cakes form on the borehole wall as the residue deposited when a slurry, such as a drilling fluid or fracturing fluid, is forced against the formation matrix under pressure. Filtrate is the liquid that passes through the matrix, leaving the cake on the borehole wall. Filter cakes may be intentionally or incidentally formed, but in most cases at some point in drilling operations it is desirable to remove filter cakes to proceed with further well operations.
Removal of polymeric filter cakes have proven to be problematic, even though various methods of removal are currently used, such as the application of acids, strong oxidative solutions, or enzymatic processes. It will be appreciated that in the context herein the term “polymeric filter cake” includes any polymeric portion of a filter cake, and that the filter cake is defined as a combination of any added solids, if any, such as proppant and drilled solids. It will also be understood that the filter cake is concentrated at the bore hole face and/or hydraulic fracture face created inside the formation. The polymers contained within such filter cakes may include, but are not necessarily limited to crosslinked and non-crosslinked polysaccharides, such as guar gum, xanthan gum and the like, or acrylamido-methyl-propane sulfonate (AMPS) polymer and the like.
It is well known that drilling and completing a well prior to production requires many steps and numerous trips of a drill string prior to production, which process may include stimulation efforts including, but not necessarily limited to, hydraulic fracturing and other activities which cause the formation of polymer filter cakes.
It would thus be very desirable and important to discover methods and compositions for combining operations to reduce the number of trips into and out of the wellbore.

SUMMARY

There is provided, in one non-limiting form, a method of installing a wellbore device on a downhole tool into a subterranean formation while also at least partially removing a polymer filter cake in proximity thereto, where the method involves positioning a downhole tool in a wellbore in proximity to the subterranean formation where a polymer filter cake has been formed adjacent thereto, the downhole tool comprising at least one shape-memory material. The method further involves introducing a composition into the wellbore to contact the at least one shape-memory material and the polymer filter cake, where the composition comprises at least one plasticizer and at least one polymer filter cake breaker; and essentially simultaneously deploying the at least one shape-memory material and at least partially removing the polymer filter cake with the composition.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a downhole tool bearing a shape-memory material (shown in cross-section) positioned in proximity to a subterranean formation having a polymer filter cake formed thereon adjacent thereto (also shown in cross-section) with an activator-breaker fluid system composition being introduced into contact therewith;

FIG. 2 is the schematic illustration of FIG. 1 where at least part of the polymer filter cake is removed from the borehole wall and the shape-memory material is at least partially deployed; and

FIG. 3 is the schematic illustration of FIG. 2 where the polymer filter cake is completely removed from the borehole wall and the shape-memory material is completely deployed.

It will be appreciated that the drawings are schematic illustrations which are not to scale and that certain features are exaggerated for clarity, and thus the methods, compositions and structures described herein should not be limited by the drawings.

DETAILED DESCRIPTION

Currently activating a shape-memory material, such as a polyurethane, is a separate step that is followed by a second wellbore clean up step. These two steps require their own trip into the wellbore.
It has been discovered that these steps may be combined into one step using a “one trip fluid” composition that can act as a plasticizer on the shape-memory material while essentially simultaneously at least partially removes polymer filter cake encountered. By “essentially simultaneously” is meant that as soon as the composition encounters both the shape-memory material and the polymer filter cake. Such encounter and contact may not be precisely simultaneously, although they are expected to be very close in time since the place where the polymer filter cake is present on the wellbore and the position of the downhole tool bearing the shape-memory material are at the same place or very close thereto. In one non-limiting embodiment, these locations are expected to be within at least about 1 foot (about 0.3 m) of each other, if not in the same place.
It is acceptable, although not strictly necessary, for all of the polymer filter cake to be removed. There may be issues with all of the polymer filter cake being sufficiently contacted by the composition so that all of the polymer filter cake is completely removed. While complete removal (100%) is certainly acceptable, it is enough that at least a majority of the polymer filter cake is removed; alternatively at least 75%, in another embodiment at least 85%, and in a different non-restrictive version, at least 95%.
The shape-memory material may include, but not necessarily be limited to, polyurethanes, polyurethanes made by reacting a polycarbonate polyol with a polyisocyanate, polystyrenes, polyethylenes, epoxies, rubbers, fluoroelastomers, nitriles, a polymer made from ethylene propylene diene monomers (EPDM), polyamides, polyureas, polyvinyl alcohols, vinyl alcohol-vinyl ester copolymers, phenolic polymers, polybenzimidazoles, polyethylene oxide/acrylic acid/methacrylic acid copolymer crosslinked with N,N′-methylene-bis-acrylamide, polyethylene oxide/methacrylic acid/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, polyethylene oxide/poly(methyl methacrylate)/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, combinations thereof, and the like. One non-limiting specific suitable shape-memory material includes the polyurethanes used in the GeoFORMT™ conformable sand management system of Baker Hughes Incorporated.
Wellbore devices, such as those used in filtration, wellbore isolation, production control, lifecycle management, wellbore construction and the like may have at least one shape-memory material that is run into the wellbore in altered geometric positions or shapes where the shape-memory material changes to its original geometric position or shape at or above a particular glass transition temperature (T_g).
The shape-memory material may be made in one non-limiting embodiment from one or more polyol, such as, but not limited to, a polycarbonate polyol and at least one isocyanate, including, but not necessarily limited to, a modified diphenylmethane diisocyanate (MDI), as well as other additives including, but not necessarily limited to, blowing agents, molecular cross linkers, chain extenders, surfactants, colorants and catalysts.
The shape-memory polyurethane material is capable of being geometrically altered, in one non-limiting embodiment compressed substantially, e.g., 20˜30% of its original volume, at temperatures above its onset glass transition temperatures (T_g) at which the material becomes soft. While still being geometrically altered, the material may be cooled down well below its onset T_g, or cooled down to room or ambient temperature, and it is able to remain in the altered geometric state even after the applied shape altering force is removed. When the material is heated near or above its onset T_g, it is capable of recovery to its original geometric state or shape, or close to its original geometric position or shape; a state or shape which may be called a recovered geometric position. In other words, the shape-memory material possesses hibernated shape-memory that provides a shape to which the shape-memory material naturally takes after its manufacturing. The compositions of polyurethane are able to be formulated to achieve desired onset glass transition temperatures which are suitable for the downhole applications, where deployment can be controlled for temperatures below onset T_gof devices at the depth at which the assembly will be used.
Generally, polyurethane polymer or polyurethane foam is considered poor in thermal stability and hydrolysis resistance, especially when it is made from polyether or polyester. It has been previously discovered herein that the thermal stability and hydrolysis resistance are significantly improved when the polyurethane is made from polycarbonate polyols and MDI diisocyanates. The compositions of polyurethane foam herein are able to be formulated to achieve different glass transition temperatures within the range from 60° C. to 170° C., which is especially suitable to meet most downhole application temperature requirements. More details about these particular polyurethane foams or polyurethane elastomers may be found in U.S. Pat. No. 7,926,565 incorporated herein by reference in its entirety.
In one specific non-limiting embodiment, the shape-memory material is a polyurethane material that is extremely tough and strong and that is capable of being geometrically altered and returned to substantially its original geometric shape. As noted, the T_gof the shape-memory polyurethane foam ranges from about 40° C. to about 200° C. and it is geometrically altered by mechanical force at 40° C. to 190° C. While still in geometrically altered state, the material may be cooled down to room temperature or some other temperature below the T_gof the shape-memory material. The shape-memory polyurethane is able to remain in the altered geometric state even after applied mechanical force is removed. When material is heated to above its onset T_g, it is able to return to its original shape, or close to its original shape. The time required for geometric shape recovery can vary from about 20 minutes to 40 hours or longer depending on the slope of the transition curves as the material moves from a glass state to a rubber state. If the material remains below the onset T_git remains in the geometrically altered state and does not change its shape.
Ideally, when shape-memory polyurethane is used as a downhole device, it is preferred that the device remains in an altered geometric state (e.g. compressed) during run-in until it reaches to the desired downhole location. Usually, downhole tools traveling from surface to the desired downhole location take hours or days. Thus, it is important to match the onset T_gs of the material with the expected downhole temperatures.
In some non-limiting embodiments, when the temperature is high enough during run-in, the devices made from the shape-memory polyurethane could start to recover. To avoid undesired early recovery during run-in, delaying methods may or must be taking into consideration. In one specific, but non-limiting embodiment, a poly(vinyl alcohol) (PVA) film or other suitable film may be used to wrap or cover the outside surface of devices made from shape-memory polyurethane to prevent recovery during run-in. Once devices are in place downhole for a given amount of time at temperature, the PVA film is capable of being dissolved in the water, emulsions or other downhole fluids and, after such exposure, the shape-memory device may recover to its original geometric shape or conform to the bore hole or other space. In another alternate, but non-restrictive specific embodiment, the devices made from the shape-memory polyurethane may be coated with a thermally fluid-degradable rigid plastic such as polyester polyurethane plastic and polyester plastic. By the term “thermally fluid-degradable plastic” is meant any rigid solid polymer film, coating or covering that is degradable when it is subjected to a fluid, e.g. water or hydrocarbon or combination thereof and heat. The covering is formulated to be degradable within a particular temperature range to meet the required application or downhole temperature at the required period of time (e.g. hours or days) during run-in. The thickness of delay covering and the type of degradable plastics or other materials may be selected to be able to keep devices of shape-memory polyurethane from recovery during run-in. Once the device is in place downhole for a given amount of time at temperature, these degradable plastics decompose which allows the devices to recover their original geometric shape or conform to the inner wall of the bore hole or the casing. In other words, the covering that inhibits or prevents the shape-memory material from returning to its original geometric position or being prematurely deployed may be removed by dissolving, e.g. in an aqueous or hydrocarbon fluid, or by thermal degradation or hydrolysis, with or without the application of heat, in another non-limiting example, destruction of the crosslinks between polymer chains of the material that makes up the covering.
The polyurethane material may be formed by combining two separate portions of chemical reactants and reacting them together. These two separate portions are referred to herein as the isocyanate portion and polyol portion. The isocyanate portion may comprise a modified isocyanate (MI) or a modified diphenylmethane diisocyanate (MDI) based monomeric diisocyanate or polyisocyanate. The polyol portion may include, but not necessarily be limited to, a polyether, polyester or polycarbonate-based di- or multifunctional hydroxyl-ended prepolymer.
Water may be included as part of the polyol portion and may act as a blowing agent to provide a porous foam structure when carbon dioxide is generated from the reaction with the isocyanate and water when the isocyanate portion and the polyol portion are combined.
In one non-restrictive embodiment, the isocyanate portion may contain modified MDI MONDUR PC sold by Bayer or MDI prepolymer LUPRANATE 5040 sold by BASF, and the polyol portion may contain (1) a poly(cycloaliphatic carbonate) polyol sold by Stahl USA under the commercial name PC-1667; (2) a tri-functional hydroxyl cross linker trimethylolpropane (TMP) sold by Alfa Aesar; (3) an aromatic diamine chain extender dimethylthiotoluenediamine (DMTDA) sold by Albemarle under the commercial name ETHACURE 300; (4) a catalyst sold by Air Products under the commercial name POLYCAT 77; (5) a surfactant sold by Air Products under the commercial name DABCO DC198; (6) a cell opener sold by Degussa under the commercial name ORTEGOL 501, (7) a colorant sold by Milliken Chemical under the commercial name REACTINT Violet X80LT, and (8) water.
The ratio between two separate portions of chemical reactants which are referred to herein as the isocyanate portion and polyol portion may, in one non-limiting embodiment, be chemically balanced close to 1:1 according to their respective equivalent weights.
The mixture containing the isocyanate portion and the polyol portion may be mixed for about 10 seconds and then poured into a mold and the mold immediately closed by placing a top metal plate thereon. Due to the significant amount of pressure generated by foaming process, a C-clamp may be used to hold the top metal plate and mold together to prevent any leakage of mixture. After approximately 2 hours at room temperature, the polyurethane foam material including a mold and a C-clamp may be placed inside an oven and “postcured” at a temperature of 110° C. for approximately 8 hours so that the polyurethane foam material reaches its full strength. These times and temperatures are simply representative and should not be taken as limiting. After cooled down to room temperature, the polyurethane material is sufficiently cured such that the mold may be removed.
At this point, the polyurethane material is in its original, expanded shape having an original, or expanded, thickness. The T_gs of the polyurethane material are measured by Dynamic Mechanical Analysis (DMA) as 94.4° C. from the peak of loss modulus, G″, in one non-restrictive version. The polyurethane material may be capable of being geometrically altered to at least 25% of original thickness or volume at temperature 125.0° C. in a confining mold. While still in the altered geometric state, the material is cooled down to room temperature. The shape-memory polyurethane is able to remain in the altered geometric state even after applied mechanical force is removed. When the material is heated to about 88° C., in one non-restrictive version, it is able to return to its original shape within 20 minutes. However, when the same material is heated to about 65° C. for about 40 hours, it does not expand or change its shape at all. In one non-limiting embodiment, a first portion of polyurethane foam may be heated to about 88° C. and thus return to its original shape and size at that temperature and a second portion of polyurethane foam may be heated to about 100° C. for sufficient time to return to its original shape and size to complete the expansion of the screen, e.g. This is possible because the different portions of the foam have different T_gs.
The mixture containing the isocyanate portion and the polyol portion may be mixed for about 10 seconds and then poured into a mold and the mold immediately closed by placing a top metal plate thereon. Due to the significant amount pressure generated by foaming process, a C-clamp or other device may be used to hold the top metal plate and mold together to prevent any leakage of mixture. After approximately 2 hours, the polyurethane foam material including a mold and a C-clamp may be transferred into an oven and “postcured” at a temperature of 110° C. for approximately 8 hours so that the polyurethane material reaches its full strength. After cooled down to room temperature, the polyurethane material is sufficiently cured such that the mold can be removed.
As may be recognized, the polyurethane having more isocyanate than polyol by weight results in higher glass transition temperature. The polyurethane having less isocyanate than polyol by weight results in lower T_g. By formulating different combinations of isocyanate and polyol, different glass transition temperatures of shape-memory polyurethane may be achieved. Compositions of a shape-memory polyurethane material having a specific T_gmay be formulated based on actual downhole deployment/application temperature. In one non-restrictive version, the T_gs of a shape-memory polyurethane is designed to be about 20° C. higher than actual downhole deployment/application temperatures. Because the application temperature is lower than T_g, the material retains good mechanical properties.
In one non-restrictive embodiment, the shape-memory polyurethane in tubular shape may be altered under hydraulic pressure above glass transition temperature, and then cooled to a temperature well below the T_gor room temperature while it is still under altering force. After the pressure is removed, the shape-memory polyurethane is able to remain at the new geometric state or shape.
Other details about polyurethane shape-memory material may be found in U.S. Pat. Nos. 7,318,481; 7,828,055 and 8,353,346 assigned to Baker Hughes Incorporated, all of which are incorporated herein by reference in their entirety.
Suitable plasticizers include, but are not necessarily limited to, methanol, methyl ethyl ketone (MEK), ethylene glycol monobutyl ether (EGMBE), toluene, isopropyl alcohol (IPA) and combinations thereof.
Suitable polymer filter cake breakers include, but are not necessarily limited to, enzymes, oxidizers and combinations thereof. Suitable specific enzyme breakers that attack the starch and the polymers in the polymer filter cake include, but are not necessarily limited to those sold as GBW-16C, GBW14C, GBW-28C, and combinations thereof available from Advanced Enzyme Systems, LLC and Baker Hughes Pressure Pumping (previously BJ Services).
In one non-limiting embodiment, the dual-function composition may comprise from about 1 independently to about 10 volume % of the at least one plasticizer and from about 1 independently to about 6 volume % of the at least one polymer filter cake breaker. Alternatively, the dual-function composition may comprise from about 1 independently to about 10 volume % of the at least one plasticizer and from about 1 independently to about 4 volume % of the at least one polymer filter cake breaker. The balance of the composition may be solvent, which may include, but not necessarily limited to, water, brine, or other aqueous solution, oil and combinations thereof.
The implementing the method of installing a wellbore device on a downhole tool in a subterranean formation while essentially simultaneously at least partially removing a polymer filter cake in proximity thereto may also include displacing a previously placed fluid prior to introducing the composition, where the previously placed fluid includes, but is not necessarily limited to, a solids free mud, a completion brine, or a combination thereof. Of course, the method herein may also further comprise producing hydrocarbons from the formation through the wellbore where the deployed shape-memory material prevents the undesirable production of solids from the formation but allows the desirable production of hydrocarbons and possibly at least some remnants of the polymer filter cake.
In a particular embodiment of the method and compositions herein, the method is accomplished with one trip of a drill string into the wellbore. This provides a significant savings in time and money compared to accomplishing the goals with separate drill string trips.
With reference to the Figures, FIG. 1 is a schematic illustration of a downhole tool 10 in a wellbore 20 having walls 22. The downhole tool 10 bears a shape-memory material 12 (shown in cross-section) positioned in proximity to a subterranean formation 14 having a polymer filter cake 16 formed on the wellbore wall 22 adjacent thereto (also shown in cross-section) with an activator-breaker fluid system composition 24 being introduced into contact therewith through the annulus 18 of a wellbore 20 from the surface in the direction of the arrows. The shape-memory material 12 is in an altered geometric position or shape, which is in a compressed position or smaller shape which enables it to be more easily positioned into the wellbore 20. Of course, subterranean formation 14 below the location of the downhole tool 10 bears valuable hydrocarbons, such as oil and gas, that are hoped to be produced.
As shown in FIG. 2, the composition 24 comprising at least one plasticizer and at least one polymer filter cake breaker, essentially simultaneously begins to deploy the shape-memory material 12′, which begins to expand to its original geometric shape and size. If it is necessary for the shape-memory material 12 to be at a particular temperature above its T_g, care should be taken that the location of the downhole tool 10 is at that temperature. However, it may be that in a particular non-limiting embodiment the plasticizer alone is sufficient to deploy the shape-memory material 12. The enzyme in the activator-breaker fluid system composition 24 also begins to at least partially remove the polymer filter cake 16′. Note that shape-memory material 12′ of FIG. 2 is larger than shape-memory material 12 of FIG. 1, and that polymer filter cake 16′ of FIG. 2 is smaller than polymer filter cake 16 of FIG. 1.
Finally, as shown in FIG. 3, the composition 14 has completed its work and polymer filter cake 16′ has been completely removed from the wellbore wall 22. Further, the shape-memory material 12″ has now fully deployed to the greatest extent possible, its shape and size being constrained by the borehole wall 22. That is, the shape-memory material 12″ has deployed and expanded back to its original size and shape as much as is possible and totally conforms to the wellbore 20. This may also be called a recovered geometric position. The deployed shape-memory material 12″ may now begin to serve its function, for instance as a filter or pack to permit the production of hydrocarbons therethrough, but which blocks sand, fines and other solids that are not desired, and which may create difficulties downstream. It is acceptable for remnants of the polymer filter cake to be produced through the deployed, porous shape memory material
Further, when it is described herein that a device “totally conforms” to the borehole or wellbore, what is meant is that the shape-memory material recovers or deploys to fill the available space up to the borehole wall. The borehole wall will limit the final, recovered shape of the shape-memory material and in fact in many cases not permit it to expand completely to its original, geometric shape. In this way however, the recovered or deployed shape-memory material, will perform the desired function within the wellbore.
The invention will now be described with respect to particular embodiments of the invention which are not intended to limit the invention in any way, but which are simply to further highlight or illustrate the invention.

Examples 1-3

The following fluids in Table I were prepared for testing with a GeoFORM™ polyurethane shape-memory material. These materials did not contain a polymer filter cake breaker; in one non-limiting embodiment, an enzyme.

TABLE I

Test compositions

One Trip Fluid	Composition

Composition A	5 vol % MEK, 9.2 ppg (1.1 kg/L) KCl
Composition B	2 vol % MEK, 9.2 ppg (1.1 kg/L) KCl
Composition C	3 vol % EGMBE, 9.2 ppg (1.1 kg/L) KCl

When these fluid Compositions contacted the same volume of GeoFORM™ polyurethane shape-memory material at the temperatures indicated below in Table II at the indicated temperature, the expansion rate in a 8.5 inch (26 cm) open hole is reported in Table II, along with the retained permeability. The polyurethane has an initial permeability. The use of the one trip fluids described herein can activate or deploy the GeoFORM polyurethane and clean up the filter cake present essentially simultaneously. Thus, with the filter cake having been exposed to these one trip fluids hydrocarbons can be flowed back through the expanded GeoFORM polyurethane and the retained permeability of the GeoFORM polyurethane is 80% or higher that of original. It may be seen that the retained permeability accomplished with these particular compositions is excellent.

TABLE II

Expansion Rate and Retained Permeability for Examples 1-3

	One Trip	Temp. ° F.		Retained
Ex.	Fluid	(° C.)	Expansion Rate, hrs	Permeability, %

1	A	110 (43)	17	95
2	B	140 (60)	7	90
3	C	140 (60)	11	90

It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. Further, the specification is to be regarded in an illustrative rather than a restrictive sense. For example, specific combinations of components to make the polyurethane shape-memory material, particular T_gs, specific downhole tool configurations, particular compositions, plasticizers, polymer filter cake breakers, designs and other compositions, components and structures falling within the claimed parameters, but not specifically identified or tried in a particular method or apparatus, are anticipated to be within the scope of this invention.
The terms “comprises” and “comprising” in the claims should be interpreted to mean including, but not limited to, the recited elements.
The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. For instance, there may be provided a method of installing a wellbore device on a downhole tool in a subterranean formation while at least partially removing a polymer filter cake adjacent thereto, where the method consists essentially of or consists of positioning a downhole tool in a wellbore in proximity to the subterranean formation where a polymer filter cake has been formed in proximity thereto, the downhole tool comprising at least one shape-memory material; introducing a composition into the wellbore to contact the at least one shape-memory material and the polymer filter cake, where the composition comprises at least one plasticizer and at least one polymer filter cake breaker; and essentially simultaneously deploying the at least one shape-memory material and at least partially removing the polymer filter cake with the composition.

Claims

What is claimed is:

1. A method of installing a wellbore device on a downhole tool in a subterranean formation while at least partially removing a polymer filter cake in proximity thereto, the method comprising:

positioning a downhole tool in a wellbore in proximity to the subterranean formation where a polymer filter cake has been formed adjacent thereto, the downhole tool comprising at least one shape-memory material;

introducing a composition into the wellbore to contact the at least one shape-memory material and the polymer filter cake, where the composition comprises at least one plasticizer and at least one polymer filter cake breaker; and

essentially simultaneously deploying the at least one shape-memory material and at least partially removing the polymer filter cake with the composition.

2. The method of claim 1 where the at least one shape-memory material is selected from the group consisting of a polyurethane, a polyurethane made by reacting a polycarbonate polyol with a polyisocyanate, a polystyrene, a polyethylene, an epoxy, a rubber, a fluoroelastomers, a nitrile, a polymer made from ethylene propylene diene monomers (EPDM), a polyamide, a polyurea, a polyvinyl alcohol, a vinyl alcohol-vinyl ester copolymer, a phenolic polymer, a polybenzimidazole, a polyethylene oxide/acrylic acid/methacrylic acid copolymer crosslinked with N,N′-methylene-bis-acrylamide, a polyethylene oxide/methacrylic acid/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, a polyethylene oxide/poly(methyl methacrylate)/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, combinations thereof.

3. The method of claim 1 where the at least one plasticizer is selected from the group consisting of methanol, methyl ethyl ketone, ethylene glycol monobutyl ether, toluene, isopropyl alcohol, and combinations thereof.

4. The method of claim 1 where the at least one polymer filter cake breaker is selected from the group consisting of enzymes, oxidizers and combinations thereof.

5. The method of claim 1 where the composition comprises:

from about 1 to about 10 volume % of the at least one plasticizer; and

from about 1 to about 6 volume % of the at least one polymer filter cake breaker.

6. The method of claim 1 further comprising displacing a previously placed fluid prior to introducing the composition, where the previously placed fluid is selected from the group consisting of a solids free mud, a completion brine, or a combination thereof.

7. The method of claim 1 further comprising producing hydrocarbons from the formation through the wellbore where the deployed shape-memory material prevents the undesirable production of solids from the formation but allows the desirable production of hydrocarbons and at least some remnants of the polymer filter cake.

8. The method of claim 1 where the method is accomplished with one trip of a drill string into the wellbore.

9. A method of installing a wellbore device on a downhole tool in a subterranean formation while at least partially removing a polymer filter cake in proximity thereto, the method comprising:

introducing a composition into the wellbore to contact the at least one shape-memory material and the polymer filter cake, where the composition comprises:

at least one plasticizer selected from the group consisting of methanol, methyl ethyl ketone, ethylene glycol monobutyl ether, toluene, isopropyl alcohol, and combinations thereof, and

at least one polymer filter cake breaker selected from the group consisting of enzymes, oxidizers and combinations thereof; and

10. The method of claim 9 where the at least one shape-memory material is selected from the group consisting of a polyurethane, a polyurethane made by reacting a polycarbonate polyol with a polyisocyanate, a polystyrene, a polyethylene, an epoxy, a rubber, a fluoroelastomers, a nitrile, a polymer made from ethylene propylene diene monomers (EPDM), a polyamide, a polyurea, a polyvinyl alcohol, a vinyl alcohol-vinyl ester copolymer, a phenolic polymer, a polybenzimidazole, a polyethylene oxide/acrylic acid/methacrylic acid copolymer crosslinked with N,N′-methylene-bis-acrylamide, a polyethylene oxide/methacrylic acid/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, a polyethylene oxide/poly(methyl methacrylate)/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, combinations thereof.

11. The method of claim 9 where the composition comprises:

from about 1 to about 10 volume % of the at least one plasticizer; and

12. The method of claim 9 further comprising displacing a previously placed fluid prior to introducing the composition, where the previously placed fluid is selected from the group consisting of a solids free mud, a completion brine, or a combination thereof.

13. The method of claim 9 further comprising producing hydrocarbons from the formation through the wellbore where the deployed shape-memory material prevents the undesirable production of solids from the formation but allows the desirable production of hydrocarbons and at least some remnants of the polymer filter cake.

14. The method of claim 9 where the method is accomplished with one trip of a drill string into the wellbore.

15. A method of installing a wellbore device on a downhole tool in a subterranean formation while at least partially removing a polymer filter cake in proximity thereto, the method comprising:

introducing a composition into the wellbore to contact the at least one shape-memory material and the polymer filter cake, where the composition comprises

from about 1 to about 10 volume % of at least one plasticizer, and

from about 1 to about 6 volume % of at least one polymer filter cake breaker; and

essentially simultaneously deploying the at least one shape-memory material and at least partially removing the polymer filter cake;

where the method is accomplished with one trip of a drill string into the wellbore with the composition.

16. The method of claim 15 where the at least one shape-memory material is selected from the group consisting of a polyurethane, a polyurethane made by reacting a polycarbonate polyol with a polyisocyanate, a polystyrene, a polyethylene, an epoxy, a rubber, a fluoroelastomers, a nitrile, a polymer made from ethylene propylene diene monomers (EPDM), a polyamide, a polyurea, a polyvinyl alcohol, a vinyl alcohol-vinyl ester copolymer, a phenolic polymer, a polybenzimidazole, a polyethylene oxide/acrylic acid/methacrylic acid copolymer crosslinked with N,N′-methylene-bis-acrylamide, a polyethylene oxide/methacrylic acid/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, a polyethylene oxide/poly(methyl methacrylate)/N-vinyl-2-pyrrolidone copolymer crosslinked with ethylene glycol dimethacrylate, combinations thereof.

17. The method of claim 15 where the at least one plasticizer is selected from the group consisting of methanol, methyl ethyl ketone, ethylene glycol monobutyl ether, toluene, isopropyl alcohol, and combinations thereof.

18. The method of claim 15 where the at least one polymer filter cake breaker is selected from the group consisting of enzymes, oxidizers and combinations thereof.

19. The method of claim 15 further comprising displacing a previously placed fluid prior to introducing the composition, where the previously placed fluid is selected from the group consisting of a solids free mud, a completion brine, or a combination thereof.

20. The method of claim 15 further comprising producing hydrocarbons from the formation through the wellbore where the deployed shape-memory material prevents the undesirable production of solids from the formation but allows the desirable production of hydrocarbons and at least some remnants of the polymer filter cake.