WO2007052048A2 - Improvements in materials for use in subterranean formations - Google Patents
Improvements in materials for use in subterranean formations Download PDFInfo
- Publication number
- WO2007052048A2 WO2007052048A2 PCT/GB2006/004116 GB2006004116W WO2007052048A2 WO 2007052048 A2 WO2007052048 A2 WO 2007052048A2 GB 2006004116 W GB2006004116 W GB 2006004116W WO 2007052048 A2 WO2007052048 A2 WO 2007052048A2
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- WIPO (PCT)
- Prior art keywords
- resin
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- drilling
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- 125000004122 cyclic group Chemical group 0.000 claims description 2
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- 150000001993 dienes Chemical class 0.000 claims description 2
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 2
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims 1
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/50—Compositions for plastering borehole walls, i.e. compositions for temporary consolidation of borehole walls
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/02—Well-drilling compositions
- C09K8/04—Aqueous well-drilling compositions
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/50—Compositions for plastering borehole walls, i.e. compositions for temporary consolidation of borehole walls
- C09K8/504—Compositions based on water or polar solvents
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/50—Compositions for plastering borehole walls, i.e. compositions for temporary consolidation of borehole walls
- C09K8/504—Compositions based on water or polar solvents
- C09K8/5045—Compositions based on water or polar solvents containing inorganic compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/50—Compositions for plastering borehole walls, i.e. compositions for temporary consolidation of borehole walls
- C09K8/504—Compositions based on water or polar solvents
- C09K8/506—Compositions based on water or polar solvents containing organic compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/50—Compositions for plastering borehole walls, i.e. compositions for temporary consolidation of borehole walls
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- C09K8/508—Compositions based on water or polar solvents containing organic compounds macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/50—Compositions for plastering borehole walls, i.e. compositions for temporary consolidation of borehole walls
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- C09K8/506—Compositions based on water or polar solvents containing organic compounds
- C09K8/508—Compositions based on water or polar solvents containing organic compounds macromolecular compounds
- C09K8/5083—Compositions based on water or polar solvents containing organic compounds macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/56—Compositions for consolidating loose sand or the like around wells without excessively decreasing the permeability thereof
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/56—Compositions for consolidating loose sand or the like around wells without excessively decreasing the permeability thereof
- C09K8/57—Compositions based on water or polar solvents
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/56—Compositions for consolidating loose sand or the like around wells without excessively decreasing the permeability thereof
- C09K8/57—Compositions based on water or polar solvents
- C09K8/572—Compositions based on water or polar solvents containing inorganic compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/56—Compositions for consolidating loose sand or the like around wells without excessively decreasing the permeability thereof
- C09K8/57—Compositions based on water or polar solvents
- C09K8/575—Compositions based on water or polar solvents containing organic compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/56—Compositions for consolidating loose sand or the like around wells without excessively decreasing the permeability thereof
- C09K8/57—Compositions based on water or polar solvents
- C09K8/575—Compositions based on water or polar solvents containing organic compounds
- C09K8/5751—Macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/56—Compositions for consolidating loose sand or the like around wells without excessively decreasing the permeability thereof
- C09K8/57—Compositions based on water or polar solvents
- C09K8/575—Compositions based on water or polar solvents containing organic compounds
- C09K8/5751—Macromolecular compounds
- C09K8/5753—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/60—Compositions for stimulating production by acting on the underground formation
- C09K8/62—Compositions for forming crevices or fractures
- C09K8/66—Compositions based on water or polar solvents
- C09K8/665—Compositions based on water or polar solvents containing inorganic compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/60—Compositions for stimulating production by acting on the underground formation
- C09K8/62—Compositions for forming crevices or fractures
- C09K8/66—Compositions based on water or polar solvents
- C09K8/68—Compositions based on water or polar solvents containing organic compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/60—Compositions for stimulating production by acting on the underground formation
- C09K8/80—Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices or the like
- E21B33/138—Plastering the borehole wall; Injecting into the formation
Definitions
- This invention relates to drilling operations conducted in oil- and gas-bearing formations, and provides improvements in materials for use in facilitating drilling operations and mitigating problems often encountered in drilling into formations which are unconsolidated or weakly pressured.
- drilling operations in oil- and gas-bearing formations can be otherwise hampered by the aforesaid instability in the formation leading to fractures in the bore.
- In-fall of material can occur dramatically upon the drill-string in weak zones of the formation, trapping the drill-string and leading to downtime whilst recovery and remedial steps are taken.
- Such potential problems may become apparent during drilling into a weakly consolidated formation, when excessive consumption of drilling fluid due to losses into the formation is observed but the ability to counter the potential collapse around the drill remains a problem to be solved reliably.
- the gellable composition and non-gellable fluids are injected alternately, the gellable composition intended to stabilise the near wellbore area, whilst the non-gellable fluid is intended to maintain a clear production flow path in the borehole.
- a method of reducing formation breakdown during a drilling operation is also described in WO 2005/012 687, where a circulating fluid including a fluid loss additive and a solid particulate material is forced under pressure into the wellbore, the intention being that fractures are formed and bridged by the particulate material which also facilitates the function of the usual fluid loss inhibitors which may precipitate upon the particulate material or fill voids around them.
- an object of the present invention is to obviate or mitigate the problems associated with drilling operations to be conducted in weakly consolidated formations .
- a further object of the invention is to provide a method of stabilising boreholes in formations susceptible to fractures during drilling.
- a further object of the invention is to provide fluids for use together for the purpose of stabilising boreholes in formations susceptible to fractures during drilling.
- a further object of at least one embodiment of the invention is to provide a method and composition capable of strengthening the near wellbore in a weak or unconsolidated formation.
- a further object of at least one embodiment of the invention is to provide a method and composition for providing reinforcement to a weak formation around a wellbore, in the form of a fused, flexible concretion or stress cage having a limited, penetration into the formation.
- the problems associated with drilling in oil-, and gas-bearing formations are addressed by providing at the wellbore surface susceptible to induced fractures a stabilising composition comprising physically interacting organic and inorganic components, which together form a flexible fused sealing composition in the induced fractures.
- a stabilising composition comprising physically interacting organic and inorganic components, which together form a flexible fused sealing composition in the induced fractures.
- a suitable composition comprises a polymerisable resin, preferably a flexible resin, such as a low molecular weight thermoplastic resin, preferably an olefinic resin, or copolymer resin provided in a particle size which enables the resin to be suspended in an aqueous fluid, the said resin being one which in use, in the presence of an initiator, and under the temperature and pressure conditions typically encountered downhole cures in the composition, to form therefrom a fused flexible concretion preferably with a degree of resilience which assists in the retentive properties thereof in situ in an induced fracture.
- a polymerisable resin preferably a flexible resin, such as a low molecular weight thermoplastic resin, preferably an olefinic resin, or copolymer resin provided in a particle size which enables the resin to be suspended in an aqueous fluid, the said resin being one which in use, in the presence of an initiator, and under the temperature and pressure conditions typically encountered downhole cures in the composition, to form therefrom a fused flexible concreti
- Thermoplastic petroleum resins (a class of hydrocarbon resins) obtained as a variable mixture of unsaturated monomers as by-product from cracked and distilled petroleum streams are one group of resins useful for the purposes of the invention.
- Such may contain indene, which is co-polymerisable with other unsaturated monomers including styrene, vinyl toluene, and methyl indene.
- These have an aromatic character but an important feature thereof in relation to this invention is the presence of an available vinyl group (unsaturated and reactive and thus available for polymerisation of the resin in the presence of an initiator under the elevated temperature and pressure conditions encountered downhole) .
- Copolymer resins such as alkylaromatic/cycloaliphatic resins, and modified alkylaromatic/cycloaliphatic resins are another useful group. Hitherto these have been typically used in printing inks and are obtainable from Neville Chemical Europe.
- thermoplastic resin mass by polymerisation between unsaturated groups of the respective resin components which may be the same or different, in the presence of a suitable initiator under elevated thermal conditions, e.g. a free-radical generator to promote polymerisation.
- the composition also contains a particulate inorganic filler material, which may be sand, aggregate fines, or other particulate matter or fibres which can be suspended in water or an aqueous fluid such as would be suitable for circulation downhole.
- composition may optionally include fluid formulation auxiliaries or other additives such as a bonding agent or setting additive or the like, suspending agents, surfactants, solvents, viscosity modifiers, or thickeners selected from those considered to be compatible with the polymerisable thermoplastic resin.
- fluid formulation auxiliaries or other additives such as a bonding agent or setting additive or the like, suspending agents, surfactants, solvents, viscosity modifiers, or thickeners selected from those considered to be compatible with the polymerisable thermoplastic resin.
- the inorganic filler is retained by the physical form of the cured resin.
- borehole temperatures can vary over a wide range in temperature and pressures, typically say from 50 - 160 0 C (perhaps 30 - 260 0 C /100 - 500 0 F in extremes) and ambient pressure to 20,000psi (-137.9MPa). Therefore, it may be preferred to have a selection of resins, same being selected to provide a group within which a resin may be selected to suit the conditions at the drilling zone (depth) . Thus one may conveniently select and provide a group of resins, respectively adapted to cure, yet remain sufficiently flexible (soften slightly) to envelope and retain particulates, in the ranges of say, 50-90 0 C, 90-120 0 C, 120-140 0 C, and 140-160 0 C or above.
- the fusible compositions intended for use under different zone conditions may vary in terms of the thermoplastic resin which may be chemically modified, branched or differ in chain length or in degree of unsaturation, and in terms of any associated auxiliaries utilised to obtain appropriate performance of the resin in the respective fusible composition.
- the fusible compositions of this invention may comprise hydrocarbon resins of low molecular weight (average 300 - 1400).
- a fusible composition for use downhole particularly for use prior to, or during a drilling operation, comprising a polymerisable thermoplastic resin, a polymerisation initiator and an inorganic filler, the said resin being one which in use under the temperature and pressure conditions typically encountered downhole cures in the composition, to form therefrom a fused flexible concretion.
- the thermoplastic resin, initiator, and inorganic filler and any other desired additives or auxiliaries are provided in a form suitable for incorporation in a fluid, which may be an aqueous fluid, e.g. water or brine, for the purposes of delivery downhole.
- a particulate, comminuted, or microbead form may be conveniently delivered in water, using if necessary a viscosifying agent or surfactant or emulsifier to provide a pumpable fluid. This is conveniently prepared on site using standard mud-mixing equipment on the rig.
- the fusible thermoplastic resin may comprise a petroleum fraction comprising unsaturated components of from eight to twelve carbon atoms, preferably at least eight to ten carbon atoms.
- the resin may comprise at least one of the following polymerisable components: vinyltoluene, indene, methylindene, alpha-methylstyrene, styrene, a cyclic conjugated diene such as an optionally alkyl- substituted dicyclopentadiene, or a mixture of any of the aforesaid components and analogues thereof.
- thermoplastic resin may comprise an aromatic mono-olefin, optionally an alkyl-substituted aromatic mono-olefin such as a di (alkyl) - dicyclopentadiene .
- the substituent may be a lower alkyl (C 1 -C 4 ) substituent, preferably a methyl group.
- the fusible composition may comprise a resin which comprises co-polymerisable components suitable for forming a copolymer alkylaromatic/cycloaliphatic resin.
- the resin may comprise co-polymerisable components, at least one of which comprises a hydroxyl group, or a carboxyl group, for forming a functionalised (modified) resin.
- the fusible composition may comprise, as the inorganic filler, a particulate material selected from sand, aggregate fines or other particulate matter or fibres which can be suspended in water or an aqueous fluid such as would be suitable for circulation downhole.
- the inorganic filler may comprise at least one of limestone, marble, granite, clay, shale, ground salt, calcium carbonate, calcium oxide, dolomite, or mixtures of the aforesaid fillers.
- the selected inorganic filler is a water-soluble filler
- it may be provided for mixing with the thermoplastic resin component (s) as a saturated or super-saturated solution, thick slurry, suspension or paste.
- the fusible composition may optionally comprise at least one additive or auxiliary selected from a bonding agent or setting additive or the like, suspending agents, surfactants, solvents, viscosity modifiers, or thickeners selected from those considered to be compatible with the thermoplastic resin.
- the additive may comprise at least one surfactant selected from anionic surfactants, non-ionic surfactants, and ionic surfactants, and may include at least one phosphate surfactant.
- the properties of the composition are such that upon introduction into the wellbore at a predetermined zone, the aqueous content of the composition seeps away or is driven off under pressure, whilst the resin and particulates become packed into the induced fractures, and in the presence of an initiator, the resin cures and provides a flexible fused compacted mass which does not shrink like cementitious compositions of the prior art.
- a fusible composition if sample-tested before use may be found to be rigid and inflexible at topside surface ambient conditions, but on account of the thermoplastic nature of the resin selected for use in a particular temperature zone, it is adequately flexible to achieve well strengthening under downhole conditions to stabilise induced fractures arising during drilling operations.
- thermoplastic resin component enables the use of the composition at a range of depths whilst ensuring that the thermoplastic resin will at the intended zone become sufficiently pliable to envelope or bind with inorganic filler components to form a stabilising concretion.
- a method of drilling in oil-, and gas-bearing formations wherein a wellbore surface susceptible to induced fractures is encountered comprises providing a dry mix of particulates comprising a thermoplastic resin and inorganic materials in a predetermined ratio together with a polymerisation initiator, introducing the dry mix to an aqueous fluid to form a liquid suspension, introducing the liquid suspension under pressure into the wellbore to contact a selected zone surface during a drilling operation, whereby induced fractures are filled with the suspension, and water is substantially driven out depositing a fusible mass of resin and inorganic materials in intimate contact, which in the presence of the initiator under conditions of temperature and pressure normally prevailing in the borehole, form a fused flexible sealing composition in the induced fractures.
- a separate liquid suspension of a particulate inorganic material such as sand, may be introduced initially, as a first step, to pack the induced fractures with sand before the suspension of fusible mass of resin and inorganic materials is introduced to the wellbore.
- a particulate inorganic material such as sand
- a kit for use in drilling in oil-, and gas-bearing formations susceptible to induced fractures comprises a plurality of dry-mix containers, each containing a fusible mix of thermoplastic resin and inorganic materials, together with an appropriate polymerisation initiator, the resin in each being adapted to cure and remain flexible within a predetermined range of temperatures, whereby the full range of conditions to be anticipated during the drilling operations can be accommodated by appropriate selection amongst the plurality of dry-mix containers.
- the mix preferably is a "ready to use" pre-mix of appropriately sized particulates, and already including any polymerisation initiator, bonding agent or setting additive required, or other auxiliaries optionally selected from surfactants, a natural or synthetic suspending agent, viscosity modifiers or thickeners, selected from those compatible with the thermoplastic resin.
- the particulate sizes are such as to permit mixing of the materials using on-rig mud handling and mixing equipment, and to be pumpable when mixed with water using circulation fluid or mud pumps. These will already be familiar to those in the art accustomed to use of such equipment on the rigs.
- a further kit including "ready for use" suspensions is provided for use in drilling in oil-, and gas-bearing formations susceptible to induced fractures, said suspensions being provided respectively in a plurality of containers, each containing an aqueous suspension of a fusible mix of thermoplastic resin and inorganic materials, the resin in each case being adapted to cure and remain flexible within a predetermined range of temperatures (as hereinbefore described) , whereby the full range of conditions to be anticipated during the drilling operations can be accommodated by appropriate selection amongst the plurality of containers containing ready-for-use suspensions.
- a separate liquid suspension of a particulate inorganic material such as sand, may be provided for use prior to the use of the suspensions of fusible mass of resin and inorganic materials.
- a separate liquid suspension serves as a pre-pack for the induced fractures to facilitate the later fusing of thermoplastic resin and inorganic particles in certain unconsolidated formations .
- the use of inert inorganic materials in any aspect of this invention may be augmented by or partially substituted by, the use of fibrous material of a size which enables the fibres to be incorporated in the suspensions of fusible materials, and subsequent operational use of the suspensions of fusible materials in the intended purpose with improved bonding.
- a kit of materials for make-up on- site as required.
- the kit includes several dry pre-mixes of materials in appropriate proportions intended to conform to a predetermined wellbore strengthening or stabilisation composition suitable for particular anticipated conditions in the wellbore.
- the dry pre- mixes are intended to be mixed into an aqueous fluid to provide a pumpable suspension using the available on-site mud mixing equipment typically found on any rig.
- the aqueous fluid may be water alone, or water including additives such as freezing point depressants provided that any such additive is verified as being compatible with the dry pre-mix before mixing takes place.
- the dry pre-mixes will comprise a thermoplastic resin selected on the basis of its ability to cure in the presence of an initiator and retain flexibility within the temperature and pressure conditions anticipated in the borehole during the drilling operation. Since the conditions vary as drilling progresses, it is necessary to have to hand more than one pre-mix, so that an appropriate one can be selected for make up as a suspension adapted to suit the conditions encountered as drilling advances through the formation.
- the resin is also selected on the basis of its ability to adhere to inert particulate inorganic materials to form upon curing under downhole conditions a fused flexible concretion thereby strengthening the wellbore.
- thermoplastic solid hydrocarbon resins when mixed in conjunction with inert aggregate material of a specific and complimentary size range.
- initial preparation steps involve selection of the thermoplastic hydrocarbon resin, which is first ground to a usable powder / particulate form capable of being placed in suspension in an aqueous fluid and typically dry mixed in the right proportions with an inert inorganic filler/aggregate material, of correspondingly appropriate particle size, in the desired ratio.
- Any necessary auxiliaries such as initiators, or a bonding agent or setting additive, surfactants, viscosity modifiers, or thickeners compatible with the resin may be included here or added later.
- the mixed materials are intended to be supplied in the mixed form in a suitable container, e.g. a bag or sack.
- the dry mixed material of powdered thermoplastic resin and inert inorganic filler/aggregate, with bonding agent or setting additive, initiator or other auxiliary as required, is then mixed in water optionally using a suitable viscosity controlling agent to give a pumpable liquid suspension. This is done on site using the standard mud mixing equipment on any rig.
- the suspension so obtained can then be selectively introduced to a weak zone to be drilled in the same manner as a circulation fluid (drilling mud) .
- This process leaves in place a solid, fused flexible concretion that displays considerable compressive strength whose overall effect is to sufficiently increase the strength of the near-wellbore formation thus allowing continuation of safe drilling of the previously weak rock formation without loss of drilling fluid.
- a general working formulation would comprise (per barrel)
- Aqueous Fluid Carrier (water / brine) : 1 barrel (-160 litres approx.)
- Fusible Thermoplastic Resin (s) 10-90 pounds per barrel (0.028 - 0.256 kg/litre)
- Aggregate Filler 25-170 pounds per barrel (0.071 - 0.485kg/litre)
- Formulation Additives (surfactant etc. ) : 0.2-4 pounds per barrel (0.0005 - O.Ollkg/litre)
- Example 2 the general procedure described in Example 1, is followed but with the following modifications.
- a liquid suspension of a particular size of sand is also mixed in water in advance of requirement. This serves as an optional fracture packing precursor for use in the well before use of the resin/aggregate suspension. Both liquid suspension mixes can be prepared in advance and held for extended periods, indefinitely with minimal agitation in fact, till needed.
- a sufficient quantity of the sand suspension is to be pumped down the well followed immediately by sufficient volume of the fusible thermoplastic resin/inert aggregate suspension.
- the sand When the plugs of the respective suspensions reach the intended downhole site, namely the induced fracture, first the sand is injected under pressure followed by the fusible thermoplastic/inert aggregate. The water is naturally filtered out at the head of the fracture leaving the sand in a compacted state (in a similar fashion to what is known as 'gravel packing'). In turn the suspended solids of thermoplastic/inert aggregate particulate mixture are also filtered out on the sand. As there is no 'filter control' material in either of these liquid suspensions the water portion of each suspension is lost leaving behind the solids which become compacted.
- thermoplastic resin and inert inorganic aggregate and sand particles are in direct contact downhole, under the prevailing pressure and temperature, in the presence of an initiator, the resin particles fuse together around the inert inorganic particles and form a strong adhesive bond.
- This process leaves in place a solid, flexible fused concretion that displays considerable compressive strength whose overall effect is to sufficiently increase the strength of the near- wellbore formation thus allowing continuation of safe drilling of the previously weak rock formation without loss of drilling fluid.
- the particulate materials to be made up into a suspension for introduction to an induced fracture zone are dosed and mixed together in the correct ratios with a carrier fluid e.g. water, on the rig and the resulting suspension of thermoplastic resin and inert inorganic materials (sand and/or aggregate) optionally comprising a suspension aid such as xanthan gum, hydroxyethyl cellulose (HEC) , or guar gum or the like, and a bonding agent or setting additive or the like, are introduced without standing over, directly to the well bore for strengthening thereof during a drilling operation.
- a carrier fluid e.g. water
- a carrier fluid e.g. water
- HEC hydroxyethyl cellulose
- guar gum guar gum
- inert durable fibres are incorporated in the mixture, the dimensions of the fibres being such as to permit suspension thereof in a substantially homogeneous way without inducing any significant detrimental effect on the suspension or otherwise inhibiting the dispersion of the thermoplastic resin and inert inorganic particles forming the fusible composition to be introduced to a zone of induced fractures for well strengthening purposes .
- the advantages of the invention described hereinbefore include 1) The fact that the particulate thermoplastic resin/inorganics are mixable to prepare as a suspension in any normal rig's mud mixing plant/equipment; 2) Its use is compatible with both WBM (water-based mud) and OBM (oil based mud) ; 3) It displays sufficient compressive strength to remain in place in the fracture without collapsing, and maintains a degree of flexibility to facilitate inhibition of ingress of unwanted fluids; 4) It is usable once it is in place downhole within an acceptable period of time, because it is heat- activated in the presence of a suitable initiator, and sets/cures more quickly than cement, and yet avoids the potential problem that some curable two part systems may have namely the risk of being 'flash' set while still in the drillpipe; 5) All the components contemplated here are currently considered to be environmentally acceptable, i.e., non-toxic, and non-hazardous to both the environment and humans .
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Abstract
A fusible composition for use downhole comprises polymerisable thermoplastic resins selected from petroleum resins, copolymer alkylaromatic/cycloaliphatic resins, modified resins containing hydroxyl or carboxyl groups, such resins being selectable to be thermally cured yet remain flexible upon curing within selected temperature ranges, say 50-90oC, 90-120oC, 120-140oC, and 140-160oC or above, a polymerisation initiator, and an inorganic filler such as particulate forms of limestone, marble, granite, clay, shale, ground salt, calcium carbonate, calcium oxide, dolomite, or mixtures of the aforesaid fillers, the resin and filler being mixable and deliverable downhole in a fluid such that in use under the temperature and pressure conditions typically encountered downhole the resin cures in the composition, to form a fused flexible concretion.
Description
Improvements in materials for use in subterranean formations
This invention relates to drilling operations conducted in oil- and gas-bearing formations, and provides improvements in materials for use in facilitating drilling operations and mitigating problems often encountered in drilling into formations which are unconsolidated or weakly pressured.
Background to the Invention
Many oil and gas fields which have been producing for a considerable time (mature assets) suffer pressure depletion in the rock structures to a considerable degree. This can become so reduced that continued drilling using the necessary density of drilling fluid can cause induced fracturing which leads to serious loss of drilling fluid. Furthermore, expansion of exploration has caused consideration to be given to naturally weak or flawed formations which are inherently susceptible to fractures.
The problems associated with weak formations often manifest themselves as "lost circulation", for example where the near wellbore rock structure is weakened to the extent that it cannot contain the overpressure of the dynamically circulating drilling fluid, thus causing induced fractures and mud losses. This problem is described for example in outline in US 5,207,282. The formations into which the drilling fluid is lost are often referred to as "lost circulation zones" or "thief zones" .
The lost circulation encountered in the drilling of a well can usually be attributed to a formation of unusually high permeability, with crevices or otherwise being highly susceptible to fractures to the extent that it is simply not sufficiently competent to support the hydrostatic pressure applied by the drilling fluid, and the bore breaks down under this hydrostatic pressure and allows the drilling fluid to flow away into the formation. US 5,207,282 proposes use of an additive to the circulation fluid in the form of a loss prevention material selected from petroleum coke, gilsonite, calcium carbonate, glass, ceramics, polymeric beads and nut shells.
One of the limiting factors in drilling a particular portion of a well is the mud weight (density of the drilling fluid) that can be used. In many cases, wells are drilled through weak or lost-circulation-prone zones prior to reaching a potential producing zone, requiring use of a low mud weight and installation of sequential casing strings to protect weaker zones above a potential producing zone. However, use of casing strings is
disadvantageous and elimination of even one casing string from a well provides important savings in time, material and costs of drilling the well. Thus whilst it is known in the art that problems of weak formations generally can be addressed by installing casings for completion and production, introduction of such structures adds labour, time and costs to the operation, and does not deal with the immediate problem encountered in the initial drilling operation.
Therefore, quite apart from the lost circulation fluid standpoint, drilling operations in oil- and gas-bearing formations can be otherwise hampered by the aforesaid instability in the formation leading to fractures in the bore. In-fall of material can occur dramatically upon the drill-string in weak zones of the formation, trapping the drill-string and leading to downtime whilst recovery and remedial steps are taken. Such potential problems may become apparent during drilling into a weakly consolidated formation, when excessive consumption of drilling fluid due to losses into the formation is observed but the ability to counter the potential collapse around the drill remains a problem to be solved reliably.
An apparently simple approach to the problem of lost circulation is to lower the density of the drilling fluid but this is not satisfactory because this can exacerbate the risk of collapse of the borehole around the drillpipe leading to trapping of the drill-pipe and significant hold-up in drilling operations whilst recovery and remedial steps are taken.
The induced fractures might possibly be sealed by pumping down cement but the attendant downtime associated with setting up and taking down the equipment for such an operation leads to excessive cost burdens. For example, to pump down cement means a lot of expensive downtime while setting up and taking down the equipment required. This can be as much as a full day and at rig rates as much as $500,000 per day this can be excessive. Furthermore, the cement can be too dense and exacerbate the induced fracture and circulation fluid losses. The density of cement can require a very large volume to be pumped to address the fracture problems, and the length of time required to cure the cement can be viewed as unacceptable for the needs of the driller.
Thus alternatives have been considered such as borehole reinforcements, e.g. gravel packs which are also expensive. Furthermore, in US 6,273,192 Bl, there is described a proposal involving injection of aqueous gellable compositions including cross-linkable polymers downhole in an effort to stabilise the wellbore and inhibit fractures. The aqueous composition described there is used together with a non-gellable fluid, such as diesel fuel for an oil-bearing formation, and a Ce or less hydrocarbon gas or an inert gas such as nitrogen for gas- bearing formations. In use, the gellable composition and non-gellable fluids are injected alternately, the gellable composition intended to stabilise the near wellbore area, whilst the non-gellable fluid is intended to maintain a clear production flow path in the borehole. A method of reducing formation breakdown during a drilling operation is also described in WO 2005/012 687, where a circulating fluid including a fluid loss additive
and a solid particulate material is forced under pressure into the wellbore, the intention being that fractures are formed and bridged by the particulate material which also facilitates the function of the usual fluid loss inhibitors which may precipitate upon the particulate material or fill voids around them.
Despite these prior art proposals to address the attendant problems of weak formation drilling, there remains to be found a reliable method of addressing them. Accordingly, an object of the present invention is to obviate or mitigate the problems associated with drilling operations to be conducted in weakly consolidated formations .
A further object of the invention is to provide a method of stabilising boreholes in formations susceptible to fractures during drilling.
A further object of the invention is to provide fluids for use together for the purpose of stabilising boreholes in formations susceptible to fractures during drilling.
A further object of at least one embodiment of the invention is to provide a method and composition capable of strengthening the near wellbore in a weak or unconsolidated formation.
A further object of at least one embodiment of the invention is to provide a method and composition for providing reinforcement to a weak formation around a wellbore, in the form of a fused, flexible concretion or
stress cage having a limited, penetration into the formation.
Summary of the Invention
According to the present invention the problems associated with drilling in oil-, and gas-bearing formations are addressed by providing at the wellbore surface susceptible to induced fractures a stabilising composition comprising physically interacting organic and inorganic components, which together form a flexible fused sealing composition in the induced fractures. This is achievable by judicious selection of thermoplastic polymerisable resin materials coupled with generally inert inorganic fillers, in particulate form sized for convenient mixing and delivery in a fluid, pumpable downhole generally in the same manner, and using the same equipment as for a drilling fluid, circulation fluid, completion fluid etc. The polymerisation is thermally activated in the presence of a suitable initiator. It is preferred to select components which will not require a chemical reaction to provide an acceptable result, hence the preference for thermoplastic resins and inorganic filler, which in use as described herein are physically interacting organic and inorganic components.
A suitable composition comprises a polymerisable resin, preferably a flexible resin, such as a low molecular weight thermoplastic resin, preferably an olefinic resin, or copolymer resin provided in a particle size which enables the resin to be suspended in an aqueous fluid, the said resin being one which in use, in the presence of an initiator, and under the temperature and pressure
conditions typically encountered downhole cures in the composition, to form therefrom a fused flexible concretion preferably with a degree of resilience which assists in the retentive properties thereof in situ in an induced fracture.
Thermoplastic petroleum resins (a class of hydrocarbon resins) obtained as a variable mixture of unsaturated monomers as by-product from cracked and distilled petroleum streams are one group of resins useful for the purposes of the invention. Such may contain indene, which is co-polymerisable with other unsaturated monomers including styrene, vinyl toluene, and methyl indene. These have an aromatic character but an important feature thereof in relation to this invention is the presence of an available vinyl group (unsaturated and reactive and thus available for polymerisation of the resin in the presence of an initiator under the elevated temperature and pressure conditions encountered downhole) . Copolymer resins such as alkylaromatic/cycloaliphatic resins, and modified alkylaromatic/cycloaliphatic resins are another useful group. Hitherto these have been typically used in printing inks and are obtainable from Neville Chemical Europe.
A common feature of these resins is the ability to form a thermoplastic resin mass by polymerisation between unsaturated groups of the respective resin components which may be the same or different, in the presence of a suitable initiator under elevated thermal conditions, e.g. a free-radical generator to promote polymerisation. The composition also contains a particulate inorganic filler material, which may be sand, aggregate fines, or
other particulate matter or fibres which can be suspended in water or an aqueous fluid such as would be suitable for circulation downhole. The composition may optionally include fluid formulation auxiliaries or other additives such as a bonding agent or setting additive or the like, suspending agents, surfactants, solvents, viscosity modifiers, or thickeners selected from those considered to be compatible with the polymerisable thermoplastic resin.
In use the inorganic filler is retained by the physical form of the cured resin.
It is known in the art that borehole temperatures can vary over a wide range in temperature and pressures, typically say from 50 - 1600C (perhaps 30 - 260 0C /100 - 5000F in extremes) and ambient pressure to 20,000psi (-137.9MPa). Therefore, it may be preferred to have a selection of resins, same being selected to provide a group within which a resin may be selected to suit the conditions at the drilling zone (depth) . Thus one may conveniently select and provide a group of resins, respectively adapted to cure, yet remain sufficiently flexible (soften slightly) to envelope and retain particulates, in the ranges of say, 50-900C, 90-1200C, 120-1400C, and 140-1600C or above. The fusible compositions intended for use under different zone conditions may vary in terms of the thermoplastic resin which may be chemically modified, branched or differ in chain length or in degree of unsaturation, and in terms of any associated auxiliaries utilised to obtain appropriate performance of the resin in the respective fusible composition.
The fusible compositions of this invention may comprise hydrocarbon resins of low molecular weight (average 300 - 1400).
Thus according to an aspect of the present invention there is provided a fusible composition for use downhole, particularly for use prior to, or during a drilling operation, comprising a polymerisable thermoplastic resin, a polymerisation initiator and an inorganic filler, the said resin being one which in use under the temperature and pressure conditions typically encountered downhole cures in the composition, to form therefrom a fused flexible concretion. The thermoplastic resin, initiator, and inorganic filler and any other desired additives or auxiliaries are provided in a form suitable for incorporation in a fluid, which may be an aqueous fluid, e.g. water or brine, for the purposes of delivery downhole. A particulate, comminuted, or microbead form may be conveniently delivered in water, using if necessary a viscosifying agent or surfactant or emulsifier to provide a pumpable fluid. This is conveniently prepared on site using standard mud-mixing equipment on the rig.
The fusible thermoplastic resin may comprise a petroleum fraction comprising unsaturated components of from eight to twelve carbon atoms, preferably at least eight to ten carbon atoms. Thus the resin may comprise at least one of the following polymerisable components: vinyltoluene, indene, methylindene, alpha-methylstyrene, styrene, a cyclic conjugated diene such as an optionally alkyl-
substituted dicyclopentadiene, or a mixture of any of the aforesaid components and analogues thereof.
An appropriate thermoplastic resin may comprise an aromatic mono-olefin, optionally an alkyl-substituted aromatic mono-olefin such as a di (alkyl) - dicyclopentadiene .
Where the resin comprises an optionally alkyl substituted molecule, the substituent may be a lower alkyl (C1-C4) substituent, preferably a methyl group.
The fusible composition may comprise a resin which comprises co-polymerisable components suitable for forming a copolymer alkylaromatic/cycloaliphatic resin. The resin may comprise co-polymerisable components, at least one of which comprises a hydroxyl group, or a carboxyl group, for forming a functionalised (modified) resin.
The fusible composition may comprise, as the inorganic filler, a particulate material selected from sand, aggregate fines or other particulate matter or fibres which can be suspended in water or an aqueous fluid such as would be suitable for circulation downhole.
The inorganic filler may comprise at least one of limestone, marble, granite, clay, shale, ground salt, calcium carbonate, calcium oxide, dolomite, or mixtures of the aforesaid fillers.
In the situation where the selected inorganic filler is a water-soluble filler, it may be provided for mixing with
the thermoplastic resin component (s) as a saturated or super-saturated solution, thick slurry, suspension or paste.
The fusible composition may optionally comprise at least one additive or auxiliary selected from a bonding agent or setting additive or the like, suspending agents, surfactants, solvents, viscosity modifiers, or thickeners selected from those considered to be compatible with the thermoplastic resin.
The additive may comprise at least one surfactant selected from anionic surfactants, non-ionic surfactants, and ionic surfactants, and may include at least one phosphate surfactant.
The properties of the composition are such that upon introduction into the wellbore at a predetermined zone, the aqueous content of the composition seeps away or is driven off under pressure, whilst the resin and particulates become packed into the induced fractures, and in the presence of an initiator, the resin cures and provides a flexible fused compacted mass which does not shrink like cementitious compositions of the prior art. Such a fusible composition if sample-tested before use may be found to be rigid and inflexible at topside surface ambient conditions, but on account of the thermoplastic nature of the resin selected for use in a particular temperature zone, it is adequately flexible to achieve well strengthening under downhole conditions to stabilise induced fractures arising during drilling operations.
Appropriate selection of the temperature range of the thermoplastic resin component enables the use of the composition at a range of depths whilst ensuring that the thermoplastic resin will at the intended zone become sufficiently pliable to envelope or bind with inorganic filler components to form a stabilising concretion.
According to one aspect of the invention, a method of drilling in oil-, and gas-bearing formations wherein a wellbore surface susceptible to induced fractures is encountered, comprises providing a dry mix of particulates comprising a thermoplastic resin and inorganic materials in a predetermined ratio together with a polymerisation initiator, introducing the dry mix to an aqueous fluid to form a liquid suspension, introducing the liquid suspension under pressure into the wellbore to contact a selected zone surface during a drilling operation, whereby induced fractures are filled with the suspension, and water is substantially driven out depositing a fusible mass of resin and inorganic materials in intimate contact, which in the presence of the initiator under conditions of temperature and pressure normally prevailing in the borehole, form a fused flexible sealing composition in the induced fractures.
Optionally, a separate liquid suspension of a particulate inorganic material, such as sand, may be introduced initially, as a first step, to pack the induced fractures with sand before the suspension of fusible mass of resin and inorganic materials is introduced to the wellbore. According to an aspect of the invention, a kit for use in drilling in oil-, and gas-bearing formations susceptible
to induced fractures comprises a plurality of dry-mix containers, each containing a fusible mix of thermoplastic resin and inorganic materials, together with an appropriate polymerisation initiator, the resin in each being adapted to cure and remain flexible within a predetermined range of temperatures, whereby the full range of conditions to be anticipated during the drilling operations can be accommodated by appropriate selection amongst the plurality of dry-mix containers. The mix preferably is a "ready to use" pre-mix of appropriately sized particulates, and already including any polymerisation initiator, bonding agent or setting additive required, or other auxiliaries optionally selected from surfactants, a natural or synthetic suspending agent, viscosity modifiers or thickeners, selected from those compatible with the thermoplastic resin. The particulate sizes are such as to permit mixing of the materials using on-rig mud handling and mixing equipment, and to be pumpable when mixed with water using circulation fluid or mud pumps. These will already be familiar to those in the art accustomed to use of such equipment on the rigs.
Since the composition of the invention is not intended to react chemically, but rather interact physically when deployed at depth during a drilling operation, it is remarkably stable topside when made up in suspension in water or an aqueous fluid with minimal need for subsequent agitation, and so according to another aspect of the invention, a further kit including "ready for use" suspensions is provided for use in drilling in oil-, and gas-bearing formations susceptible to induced fractures, said suspensions being provided respectively in a
plurality of containers, each containing an aqueous suspension of a fusible mix of thermoplastic resin and inorganic materials, the resin in each case being adapted to cure and remain flexible within a predetermined range of temperatures (as hereinbefore described) , whereby the full range of conditions to be anticipated during the drilling operations can be accommodated by appropriate selection amongst the plurality of containers containing ready-for-use suspensions.
Optionally, a separate liquid suspension of a particulate inorganic material, such as sand, may be provided for use prior to the use of the suspensions of fusible mass of resin and inorganic materials. Such a separate liquid suspension serves as a pre-pack for the induced fractures to facilitate the later fusing of thermoplastic resin and inorganic particles in certain unconsolidated formations . The use of inert inorganic materials in any aspect of this invention may be augmented by or partially substituted by, the use of fibrous material of a size which enables the fibres to be incorporated in the suspensions of fusible materials, and subsequent operational use of the suspensions of fusible materials in the intended purpose with improved bonding.
The invention will now be further explained by way of the following examples which are intended to provide illustrative embodiments of the invention to demonstrate how performance of the invention may be put into practice.
Example 1
In a first embodiment of the invention, to be applied in a drilling operation to be conducted in a formation anticipated as being poorly consolidated, e.g. containing dolomitic limestone or the like readily fractured rock structure, a kit of materials is provided for make-up on- site as required. The kit includes several dry pre-mixes of materials in appropriate proportions intended to conform to a predetermined wellbore strengthening or stabilisation composition suitable for particular anticipated conditions in the wellbore. The dry pre- mixes are intended to be mixed into an aqueous fluid to provide a pumpable suspension using the available on-site mud mixing equipment typically found on any rig. The aqueous fluid may be water alone, or water including additives such as freezing point depressants provided that any such additive is verified as being compatible with the dry pre-mix before mixing takes place.
The dry pre-mixes will comprise a thermoplastic resin selected on the basis of its ability to cure in the presence of an initiator and retain flexibility within the temperature and pressure conditions anticipated in the borehole during the drilling operation. Since the conditions vary as drilling progresses, it is necessary to have to hand more than one pre-mix, so that an appropriate one can be selected for make up as a suspension adapted to suit the conditions encountered as drilling advances through the formation. The resin is also selected on the basis of its ability to adhere to inert particulate inorganic materials to form upon curing
under downhole conditions a fused flexible concretion thereby strengthening the wellbore.
Thus the solution to the problem is based on the utilisation of the physical bonding properties of selected thermoplastic solid hydrocarbon resins when mixed in conjunction with inert aggregate material of a specific and complimentary size range.
In practice of the invention, initial preparation steps involve selection of the thermoplastic hydrocarbon resin, which is first ground to a usable powder / particulate form capable of being placed in suspension in an aqueous fluid and typically dry mixed in the right proportions with an inert inorganic filler/aggregate material, of correspondingly appropriate particle size, in the desired ratio. Any necessary auxiliaries such as initiators, or a bonding agent or setting additive, surfactants, viscosity modifiers, or thickeners compatible with the resin may be included here or added later. The mixed materials are intended to be supplied in the mixed form in a suitable container, e.g. a bag or sack.
The dry mixed material of powdered thermoplastic resin and inert inorganic filler/aggregate, with bonding agent or setting additive, initiator or other auxiliary as required, is then mixed in water optionally using a suitable viscosity controlling agent to give a pumpable liquid suspension. This is done on site using the standard mud mixing equipment on any rig.
The suspension so obtained can then be selectively introduced to a weak zone to be drilled in the same
manner as a circulation fluid (drilling mud) . This process leaves in place a solid, fused flexible concretion that displays considerable compressive strength whose overall effect is to sufficiently increase the strength of the near-wellbore formation thus allowing continuation of safe drilling of the previously weak rock formation without loss of drilling fluid.
Typically, a general working formulation would comprise (per barrel)
Aqueous Fluid Carrier (water / brine) : 1 barrel (-160 litres approx.)
Fusible Thermoplastic Resin (s) : 10-90 pounds per barrel (0.028 - 0.256 kg/litre)
Aggregate Filler: 25-170 pounds per barrel (0.071 - 0.485kg/litre)
Formulation Additives (surfactant etc. ) : 0.2-4 pounds per barrel (0.0005 - O.Ollkg/litre)
Polymerisation initiator: trace amount
Suitable formulations for performing the invention are given by way of example in the following Table, wherein "bbl" = 1 barrel (approx. 160 litres or 35 imperial gallons) and "ppb" = pounds per barrel (1 pound per barrel approximates to 0.002853 kg/litre).
Table
In an alternative embodiment of the invention, the general procedure described in Example 1, is followed but with the following modifications. A liquid suspension of a particular size of sand is also mixed in water in advance of requirement. This serves as an optional fracture packing precursor for use in the well before use of the resin/aggregate suspension. Both liquid suspension mixes can be prepared in advance and held for extended periods, indefinitely with minimal agitation in fact, till needed. Thus, in practice of this embodiment, when it is required to be used, firstly, a sufficient quantity of the sand suspension is to be pumped down the well followed immediately by sufficient volume of the fusible thermoplastic resin/inert aggregate suspension.
When the plugs of the respective suspensions reach the intended downhole site, namely the induced fracture, first the sand is injected under pressure followed by the fusible thermoplastic/inert aggregate. The water is naturally filtered out at the head of the fracture leaving the sand in a compacted state (in a similar fashion to what is known as 'gravel packing'). In turn the suspended solids of thermoplastic/inert aggregate particulate mixture are also filtered out on the sand. As there is no 'filter control' material in either of these liquid suspensions the water portion of each suspension is lost leaving behind the solids which become compacted.
Once the thermoplastic resin and inert inorganic aggregate and sand particles are in direct contact downhole, under the prevailing pressure and temperature, in the presence of an initiator, the resin particles fuse together around the inert inorganic particles and form a strong adhesive bond. This process leaves in place a solid, flexible fused concretion that displays considerable compressive strength whose overall effect is to sufficiently increase the strength of the near- wellbore formation thus allowing continuation of safe drilling of the previously weak rock formation without loss of drilling fluid.
Example 3
In a variant of the invention, the particulate materials to be made up into a suspension for introduction to an induced fracture zone are dosed and mixed together in the correct ratios with a carrier fluid e.g. water, on the rig and the resulting suspension of thermoplastic resin and inert inorganic materials (sand and/or aggregate) optionally comprising a suspension aid such as xanthan gum, hydroxyethyl cellulose (HEC) , or guar gum or the like, and a bonding agent or setting additive or the like, are introduced without standing over, directly to the well bore for strengthening thereof during a drilling operation.
Example 4
In a further variant of the invention, inert durable fibres are incorporated in the mixture, the dimensions of the fibres being such as to permit suspension thereof in
a substantially homogeneous way without inducing any significant detrimental effect on the suspension or otherwise inhibiting the dispersion of the thermoplastic resin and inert inorganic particles forming the fusible composition to be introduced to a zone of induced fractures for well strengthening purposes .
The advantages of the invention described hereinbefore include 1) The fact that the particulate thermoplastic resin/inorganics are mixable to prepare as a suspension in any normal rig's mud mixing plant/equipment; 2) Its use is compatible with both WBM (water-based mud) and OBM (oil based mud) ; 3) It displays sufficient compressive strength to remain in place in the fracture without collapsing, and maintains a degree of flexibility to facilitate inhibition of ingress of unwanted fluids; 4) It is usable once it is in place downhole within an acceptable period of time, because it is heat- activated in the presence of a suitable initiator, and sets/cures more quickly than cement, and yet avoids the potential problem that some curable two part systems may have namely the risk of being 'flash' set while still in the drillpipe; 5) All the components contemplated here are currently considered to be environmentally acceptable, i.e., non-toxic, and non-hazardous to both the environment and humans .
Claims
1. A fusible composition for use downhole comprising a polymerisable thermoplastic resin, and an inorganic filler, the said resin being one which in use in the presence of an initiator under the temperature and pressure conditions typically encountered downhole cures in the composition, to form therefrom a fused flexible concretion.
2. A composition according to claim 1, wherein the resin comprises a low molecular weight thermoplastic resin (say average 300 - 1400) .
3. A composition according to claim 1, wherein the resin comprises an olefinic resin.
4. A composition according to claim 1, wherein the resin comprises an aromatic monoolefin, optionally alkyl-substituted.
5. A composition according to claim 4, wherein the resin comprises a petroleum fraction comprising unsaturated components of from eight to twelve carbon atoms.
6. A composition according to claim 5, wherein the resin comprises at least one of the following polymerisable components: vinyltoluene, indene, methylindene, alpha-methylstyrene, styrene, a cyclic conjugated diene such as an optionally alkyl- substituted dicyclopentadiene, or a mixture of any of the aforesaid components.
7. A composition according to claim 4, or claim 6, wherein the alkyl substitution is a lower alkyl (Ci- C4) substituent.
8. A composition according to claim 7, wherein the substituent is a methyl group.
9. A composition according to claim 1, wherein the resin comprises co-polymerisable components for a copolymer alkylaromatic/cycloaliphatic resin.
10. A composition according to claim 1, wherein the resin comprises co-polymerisable components, at least one of which comprises a hydroxyl group, or a carboxyl group, for forming a functionalised (modified) resin.
11. A composition according to any one of claims 1 to 10, wherein the inorganic filler is a particulate material selected from sand, aggregate fines or other particulate matter or fibres which can be suspended in water or an aqueous fluid such as would be suitable for circulation downhole.
12. A composition according to claim 11, wherein the inorganic filler is at least one of limestone, marble, granite, clay, shale, ground salt, calcium carbonate, calcium oxide, dolomite, or mixtures of the aforesaid fillers.
13. A composition according to claim 12, wherein the inorganic filler is a water-soluble filler, provided as a saturated solution or suspension.
14. A composition according to any one of claims 1 to 11, comprising at least one additive or auxiliary selected from a bonding agent or setting additive or the like, suspending agents, surfactants, solvents, viscosity modifiers, or thickeners, selected from those considered to be compatible with the thermoplastic resin.
15. A composition according to claim 14, wherein the additive comprises at least one surfactant.
16. A composition according to claim 15, wherein at least one surfactant is a phosphate surfactant, whilst others are selected from anionic surfactants, and non-ionic surfactants
17. A composition according to any one of claims 1 to 16, wherein the resin is selected from a range of resins having properties adapted for use at different depths of drilling, to operate at an ambient pressure of up to 20,000psi (-137.9MPa), and respectively adapted to cure, yet remain sufficiently flexible (soften slightly) to envelope and retain particulates, in the temperature ranges, 50-900C, 90-1200C, 120-1400C, and 140-1600C or above .
18. A composition according to claim 17, comprising per barrel (-160 litres approx. ) of water, fusible thermoplastic resin(s) in the range of 10-90 pounds per barrel (-0.028 - 0.256 kg/litre), aggregate fillers in the range of 25-170 pounds per barrel (-0.071 - 0.485kg/litre) and formulation additives (surfactant etc.) in the range of 0.2-4 pounds per barrel (-0.0005 - 0. Ollkg/litre) , and a sufficient amount of polymerisation initiator.
19. A composition according to claim 17, wherein a copolymer resin and/or a petroleum resin is present in an amount of from 40 - 120 ppb (-0.11 - 0.34 kg/litre) , fillers consisting of barite, chalk powder, and silica sand in an amount of from 100 - 310 ppb (-0.28 - 0.88 kg/litre), a phosphate surfactant in an amount of from 0.5 - 3 ppb (0.001 - 0.008 kg/litre) an anionic surfactant in an amount of from 0.1 - 1.5 ppb (0.0002 - 0.004 kg/litre), and a non-ionic surfactant in an amount of from 0.1 - 2.5 ppb (0.0002 - 0.007 kg/litre), and xanthan gum in an amount of from 1 - 3 ppb (0.002 - 0.008 kg/litre), the balance being water per barrel (50-80%) and a sufficient amount of initiator.
20. A method of drilling in oil-, and gas-bearing formations wherein a wellbore surface susceptible to induced fractures is encountered wherein the method comprises providing a dry mix of particulates comprising a thermoplastic polymerisable resin with an initiator, and inorganic materials in a predetermined ratio, introducing the dry mix to an aqueous fluid to form a liquid suspension, introducing the liquid suspension under pressure into the wellbore to contact a selected zone surface during a drilling operation, whereby induced fractures are filled with the suspension, and water is substantially driven out depositing a fusible mass of resin and inorganic materials in intimate contact, which under conditions of temperature and pressure normally prevailing in the borehole, form a fused flexible sealing composition in the induced fractures, wherein the composition is a composition as claimed in any one of claims 1 to 19.
21. A method according to claim 20, wherein a separate liquid suspension of a particulate inorganic material, is introduced initially to pack the induced fractures before the suspension of fusible mass of resin and inorganic materials is introduced to the wellbore.
22. A kit for use in drilling in oil-, and gas-bearing formations susceptible to induced fractures comprises a plurality of dry-mix containers, each containing a fusible mix of thermoplastic polymerisable resin, a polymerisation initiator, and inorganic materials, the resin in each being adapted to cure and remain flexible within a predetermined range of temperatures, whereby the full range of conditions to be anticipated during the drilling operations can be accommodated by appropriate selection amongst the plurality of dry-mix containers, wherein the fusible mix comprises a composition according to any one of claims 1 to 19.
23. A kit according to claim 22, wherein the mix is a "ready to use" pre-mix of appropriately sized particulates, including additive or other auxiliaries required, wherein the particulate sizes are such as to permit mixing of the materials using on-rig mud handling and mixing equipment, and to be pumpable when mixed with water using circulation fluid or mud pumps.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0522653.5 | 2005-11-07 | ||
| GBGB0522653.5A GB0522653D0 (en) | 2005-11-07 | 2005-11-07 | Improvements in materials for use in subterranean formations |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2007052048A2 true WO2007052048A2 (en) | 2007-05-10 |
| WO2007052048A3 WO2007052048A3 (en) | 2007-11-08 |
Family
ID=35516455
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/GB2006/004116 WO2007052048A2 (en) | 2005-11-07 | 2006-11-06 | Improvements in materials for use in subterranean formations |
Country Status (2)
| Country | Link |
|---|---|
| GB (2) | GB0522653D0 (en) |
| WO (1) | WO2007052048A2 (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2009101382A1 (en) * | 2008-02-15 | 2009-08-20 | Halliburton Energy Services, Inc. | Compositions and applications of resins in treating subterranean formations |
| US9181469B2 (en) | 2008-02-29 | 2015-11-10 | Tucc Technology, Llc | Methods, systems, and compositions for the controlled crosslinking of well servicing fluids |
| CN108641684A (en) * | 2018-04-26 | 2018-10-12 | 廊坊庆兴化工有限公司 | A kind of drilling fluid compound resin lubricating collapse-resisting agent and preparation method thereof |
| CN111139043A (en) * | 2018-11-06 | 2020-05-12 | 中国石油化工股份有限公司 | Plugging anti-collapse treating agent for shale stratum and preparation method thereof |
| CN112322264A (en) * | 2020-12-08 | 2021-02-05 | 中国石油天然气集团有限公司 | Borehole wall reinforcing working solution and preparation method thereof |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8333241B2 (en) | 2006-02-10 | 2012-12-18 | Halliburton Energy Services, Inc. | Methods and compositions for packing void spaces and stabilizing formations surrounding a wellbore |
| US7819192B2 (en) | 2006-02-10 | 2010-10-26 | Halliburton Energy Services, Inc. | Consolidating agent emulsions and associated methods |
| WO2010075256A1 (en) | 2008-12-23 | 2010-07-01 | 3M Innovative Properties Company | Particles comprising blocked isocyanate resin and method of modifying a wellbore using the same |
| WO2010075248A1 (en) | 2008-12-23 | 2010-07-01 | 3M Innovative Properties Company | Curable fiber and compositions comprising the same; method of trating a subterranean formation |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4192753A (en) * | 1978-03-07 | 1980-03-11 | Union Oil Company Of California | Well completion and workover fluid having low fluid loss |
| US6036765A (en) * | 1998-04-01 | 2000-03-14 | Southern Clay Products | Organoclay compositions and method of preparation |
| WO2005121198A1 (en) * | 2004-06-03 | 2005-12-22 | Shell Internationale Research Maatschappij B.V. | Geosynthetic composite for borehole strengthening |
| WO2005122313A2 (en) * | 2004-06-03 | 2005-12-22 | Shell Internationale Research Maatschappij B.V. | Method and apparatus for performing chemical treatments of exposed geological formations |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3907989A1 (en) * | 1989-03-11 | 1990-09-13 | Henkel Kgaa | AQUEOUS RESIN PREPARATIONS FOR STONE SOLIDIFICATION AND CAVITY FILLING AND METHOD THEREFOR |
-
2005
- 2005-11-07 GB GBGB0522653.5A patent/GB0522653D0/en not_active Ceased
-
2006
- 2006-11-06 GB GB0622056A patent/GB2431949B/en not_active Expired - Fee Related
- 2006-11-06 WO PCT/GB2006/004116 patent/WO2007052048A2/en active Application Filing
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4192753A (en) * | 1978-03-07 | 1980-03-11 | Union Oil Company Of California | Well completion and workover fluid having low fluid loss |
| US6036765A (en) * | 1998-04-01 | 2000-03-14 | Southern Clay Products | Organoclay compositions and method of preparation |
| WO2005121198A1 (en) * | 2004-06-03 | 2005-12-22 | Shell Internationale Research Maatschappij B.V. | Geosynthetic composite for borehole strengthening |
| WO2005122313A2 (en) * | 2004-06-03 | 2005-12-22 | Shell Internationale Research Maatschappij B.V. | Method and apparatus for performing chemical treatments of exposed geological formations |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2009101382A1 (en) * | 2008-02-15 | 2009-08-20 | Halliburton Energy Services, Inc. | Compositions and applications of resins in treating subterranean formations |
| US9181469B2 (en) | 2008-02-29 | 2015-11-10 | Tucc Technology, Llc | Methods, systems, and compositions for the controlled crosslinking of well servicing fluids |
| US10253248B2 (en) | 2008-02-29 | 2019-04-09 | Tucc Technology, Llc | Methods, systems, and compositions for the controlled crosslinking of well servicing fluids |
| CN108641684A (en) * | 2018-04-26 | 2018-10-12 | 廊坊庆兴化工有限公司 | A kind of drilling fluid compound resin lubricating collapse-resisting agent and preparation method thereof |
| CN111139043A (en) * | 2018-11-06 | 2020-05-12 | 中国石油化工股份有限公司 | Plugging anti-collapse treating agent for shale stratum and preparation method thereof |
| CN112322264A (en) * | 2020-12-08 | 2021-02-05 | 中国石油天然气集团有限公司 | Borehole wall reinforcing working solution and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0522653D0 (en) | 2005-12-14 |
| WO2007052048A3 (en) | 2007-11-08 |
| GB0622056D0 (en) | 2006-12-13 |
| GB2431949A (en) | 2007-05-09 |
| GB2431949B (en) | 2008-02-20 |
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