WO2020018110A1

WO2020018110A1 - Degradable metal body for sealing of shunt tubes

Info

Publication number: WO2020018110A1
Application number: PCT/US2018/042990
Authority: WO
Inventors: Michael Linley Fripp; Stephen Michael Greci; Pete Clement Dagenais
Original assignee: Halliburton Energy Services, Inc.
Priority date: 2018-07-20
Filing date: 2018-07-20
Publication date: 2020-01-23
Also published as: GB202017943D0; AU2018433057A1; CA3100655A1; GB2587971A; CA3100655C; MY195249A; GB2587971B

Abstract

A method of sealing an interior passageway of a shunt tube that forms a portion of a completion assembly includes positioning the completion assembly within a wellbore, wherein the completion assembly includes: the shunt tube; and a degradable metal body associated with the shunt tube; performing, using the completion assembly, gravel packing operations; and permitting the degradable metal body to corrode so that the degradable metal body produces particles comprising a metal element and a plug is formed within the interior passageway of the shunt tube, wherein the plug includes the particles. The plug also includes proppant from the gravel packing operations.

Description

DEGRADABLE METAL BODY FOR SEALING OF SHUNT TUBES

TECHNICAL FIELD

[0001] The present disclosure relates generally to a sealing mechanism for shunt tubes, and specifically to a degradable metal body used to seal shunt tubes and other downhole passageways.

BACKGROUND

[0002] Shunt tubes are used in gravel packing operations to facilitate even distribution of gravel in an annulus between well screens and a wellbore. In some circumstances, it is desirable to close off the annulus between well screens after the gravel packing operation (for example, to provide isolation between gravel packed zones).

[0003] Closing shunt tubes after gravel packing is often difficult, but is needed to prevent cross flow in a gravel packed completion assembly. That is, to fluidically isolate two zones that are separated by packers, the shunt tubes that extend through the packers should also be fluidically isolated to prevent flow between zones via the shunt tubes. Elastomeric approaches to closing the shunt tubes are difficult due to the likelihood of gravel being in the tubes.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 is a schematic illustration of an offshore oil and gas platform operably coupled to a lower completion assembly according to an embodiment of the present disclosure;

[0005] FIG. 2 illustrates a perspective view of a portion of the lower completion assembly of FIG. 1, according to an example embodiment of the present disclosure, the lower completion assembly including a degradable metal body;

[0006] FIG. 3 illustrates a perspective view of the degradable metal body of FIG. 2, according to an example embodiment of the present disclosure;

[0007] FIG. 4 illustrates a sectional view of the lower completion assembly of FIG. 1 in a first configuration, according to an example embodiment of the present disclosure; [0008] FIG. 5 is a flow chart illustration of a method of operating the apparatus of FIGS. 1-4, according to an example embodiment;

[0009] FIG. 6 illustrates a sectional view of the lower completion assembly of FIG. 1 in a second configuration, according to an example embodiment of the present disclosure;

[0010] FIG. 7 illustrates a perspective view of a portion of the lower completion assembly of FIG. 1 according to another example embodiment, the portion of the lower completion assembly including a shunt tube and a degradable metal body; and

[0011] FIG. 8 illustrates a sectional view of the shunt tube and the degradable metal body of FIG. 7, according to an example embodiment.

DETAILED DESCRIPTION

[0012] Referring initially to FIG. 1, an upper completion assembly is installed in a well having a lower completion assembly disposed therein from an offshore oil or gas platform that is schematically illustrated and generally designated 10. However, and in some cases, a single trip completion assembly (i.e., not having separate upper and lower completion assemblies) are installed in the well. A semi-submersible platform 15 is positioned over a submerged oil and gas formation 20 located below a sea floor 25. A subsea conduit 30 extends from a deck 35 of the platform 15 to a subsea wellhead installation 40, including blowout preventers 45. The platform 15 has a hoisting apparatus 50, a derrick 55, a travel block 56, a hook 60, and a swivel 65 for raising and lowering pipe strings, such as a substantially tubular, axially extending tubing string 70.

[0013] A wellbore 75 extends through the various earth strata including the formation 20 and has a casing string 80 cemented therein. Disposed in a substantially horizontal portion of the wellbore 75 is a lower completion assembly 85 that includes a degradable metal body and that includes at least one screen assembly, such as screen assembly 90 or screen assembly 95 or screen assembly 100, and may include various other components, such as a latch subassembly 105, a packer 110, a packer 115, a packer 120, and a packer 125.

[0014] Disposed in the wellbore 75 is an upper completion assembly 130 that couples to the latch subassembly 105 to place the upper completion assembly 130 and the tubing string 70 in communication with the lower completion assembly 85. In some embodiments, the latch subassembly 105 is omitted.

[0015] Even though FIG. 1 depicts a horizontal wellbore, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in wellbores having other orientations including vertical wellbores, slanted wellbores, uphill wellbores, multilateral wellbores or the like. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as“above,”“below,”“upper,”“lower,” “upward,”“downward,”“uphole,”“downhole” and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure, the uphole direction being toward the surface of the well, the downhole direction being toward the toe of the well. Also, even though FIG. 1 depicts an offshore operation, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in onshore operations. Further, even though FIG. 1 depicts a cased hole completion, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in open hole completions.

[0016] FIG. 2 illustrates a portion of the lower completion assembly 85. The lower completion assembly 85 includes a production tubing 135, a shunt tube 145 that forms a passageway 150 (illustrated in FIGS. 4 and 6), a shunt tube 155 that forms a passageway 160 (illustrated in FIGS. 4 and 6), a degradable metal body 165 that is associated with the shunt tube 145, and a degradable metal body 170 that is associated with the shunt tube 155. FIG. 3 illustrates a perspective view of the degradable metal body 165. FIG. 4 illustrates a cross-sectional view of the lower completion assembly 85 that includes a shroud 175 surrounding the production tubing 135, the shunt tubes 145 and 155, and the degradable metal bodies 165 and 170 (not shown in FIG. 4). In some embodiments, the degradable metal body 165 is comprised of a metal and surrounds at least a portion of the shunt tube 145. In some embodiments, the degradable metal body 165 completely encloses the shunt tube 145. As such, and as illustrated in FIGS. 3 and 4, the degradable metal body 165 has a body 180 through which a passageway 185 extends. At least a portion of the shunt tube 145 extends through the passageway 185. However, in other embodiments, the degradable metal body 165 can be inserted into the passageway 150 of the shunt tube 145, can be positioned on the ends of the shunt tube 145, can be at the junctions in the shunt tube 145, etc.

[0017] As illustrated in FIG. 4, the shunt tube 145 is perforated such that a plurality of holes 190 are formed in the portion of the shunt tube 145 that extends through the passageway 185.

[0018] In some embodiments, the degradable metal body 165 is spaced longitudinally from the degradable metal body 170 while in other embodiments, the degradable metal bodies 165 and 170 are aligned longitudinally.

[0019] In an example embodiment, as illustrated in FIG. 5 with continuing reference to FIGS. 1-4, a method 500 of using hydrolysis of the degradable metal body 165 to seal the shunt tube 145 includes positioning the lower completion assembly 85 within the wellbore 75 at step 505; performing gravel packing operations at step 510; corroding the degradable metal body 165 to produce metal particles at step 515; and creating a metal plug that extends within a radial cross- section of the interior passageway 150 at step 520.

[0020] At the step 505, the lower completion assembly is positioned within the wellbore 75. Generally, the lower completion assembly is positioned within the wellbore 75 when in the first configuration.

[0021] At the step 510, gravel packing operations are performed. Generally, proppant is positioned within the shunt tubes 145 and 155 during the gravel packing operations. Pore spaces are formed between the pieces of proppant used during the gravel packing operations. A proppant includes particles, proppants, sand, gravel, or any combination thereof. Generally, the size of the pore spaces that are formed for each type or size of proppants is predictable or can be estimated.

[0022] At the step 515, the degradable metal body 165 is corroded, or permitted to corrode, to produce particles of the corroded metal or particles comprising a metal element, such as metal hydroxide particles or, equivalently, metal hydrate particles. Generally, the corrosion occurs due to exposure to a downhole fluid in the interior passageway 150 of the shunt tube 145. In one example embodiment, the degradable metal bodies 165 and 170 are composed or formed from an alkaline earth metal (e.g., Mg, Ca, etc.) or a transition metal (e.g., Al, etc.). In one application, the material of the degradable metal body 165 is a magnesium alloy including magnesium alloys that are alloyed with Al, Zn, Mn, Zr, Y, Nd, Gd, Ag, Ca, Sn, and RE. In some applications, the alloy is further alloyed with a dopant that promotes galvanic reaction, such as Ni, Fe, Cu, Co, Ir, Au, and Pd. In some embodiments, the magnesium alloy can be constructed in a solid solution process where the elements are combined with molten magnesium or magnesium alloy. Alternatively, the magnesium alloy could be constructed with a powder metallurgy process. Alternatively, the starting metal may be a metal oxide. For example, calcium oxide (CaO) with water will produce calcium hydroxide in an energetic reaction. Many metals will react with water to form a metal hydroxide and/or a metal oxide. Thus, water is one example of a corrosive fluid. This galvanic corrosion process results in the hydroxide material being released from the base metal. The products of the metal hydration reaction are fines that have a diameter between 1 micron and 1000 microns. In some embodiments, additional ions, including silicate, sulfate, aluminate, phosphate, are added to the material from which the degradable metal body 165 is composed. In some embodiments, the degradable metal body 165 is alloyed to increase the reactivity or to control the formation of oxides. For example, and when the degradable metal body 165 includes aluminum, then mercury, gallium, and other transition and post transition metals can be added in order to control the oxide formation. In some cases, the metal is heat treated to change the grain size of the particles such as through annealing, solution treating, aging, quenching, and hardening.

[0023] At the step 520 and as illustrated in FIG. 6, a metal plug 525, or a plug that includes the particles created from the corroding of the metal body 165, is created, or permitted to form, that extends within the radial cross-section of the passageway 150 of the shunt tube 145 and that comprises metal particles 530. In some embodiments, the metal particles 530 are the particles released from the degradable metal body 165 during the step 515. The metal particles 530 or fines will accumulate and fill the space between the pores of proppant 535. When enough fines accumulate, they lock together and form the cement-like seal or metal plug 525. In some embodiments, the combination of the corroded metal particles is a type of cemented plug. That is, as the metal hydroxide particles continues to be produced and continues to fill the void spaces, the particles get squeezed together. This squeezing together locks the hydroxide particles into a solid seal. In one embodiment, the metal hydroxide or metal particles 530 are dehydrated by the swellable pressure to form a metal oxide. The accumulation of the metal particles 530 in the pores of the proppant 535, is dependent upon the size of the metal particles 530 and the size of the pores of the proppant. Thus, and in some embodiments, the material from which the degradable metal body 165 is formed is determined or selected based on the expected pore size of the proppant. In some embodiments, the metal particles 530 accumulate in the pores of the proppant 535 and form a proppant and metal particle plug in the cross-section of the shunt tube 145. However, in other embodiments, the metal plug 525 is formed in the cross-section of the shunt tube 145 without proppant being accommodated in the cross-section of the shunt tube 145. Regardless of whether the plug 525 comprises proppant, the plug 525 is formed from the locking of the metal particles 530 accumulating and locking together in the radial cross-section of the passageway 150 of the shunt tube 145. In one variation, the metal plug 525, or sluff-able metal seal, is formed in a serpentine reaction. In another variation, at least a portion of the metal plug 525 is a mafic material.

[0024] In an alternative embodiment, galvanic potential is used to encourage the deposition of salts onto the surface of the degradable metal body 165. Salts within the wellbore fluids will form on the surface of the degradable metal body 165 to create a plug that extends across a radial cross-section of the passageway 150 of the shunt tube 145. Thus, in some embodiments a plating process resulting in the salts in the wellbore fluid being depositing on the radial cross-section of the passageway 150 of the shunt tube 145 via an electrochemical process to form the plug 525. In some embodiments, the salts are deposited in the form of a scale.

[0025] In some embodiments and as illustrated in FIGS. 7 and 8, the degradable metal bodies 165 and 170 form a portion of a jumper tube assembly in which jumper tubes, or the shunt tubes 145 and 155, span the handling space and coupling gap between two screen joints. In this embodiment and as illustrated in FIG. 8, the degradable metal body 165 forms a portion of the interior passageway 150. As illustrated, the interior passageway 150 formed with the degradable metal body 165 is widened and narrowed relative to other portions of the passageway 150 formed through the remainder of the shunt tube 145 so the magnesium or metal particles have less distance to travel through the proppant, while still maintaining adequate flow area for the gravel slurry delivery function of the shunt tube 145. That is, measured from a centerline 600 of the passageway 150, a first portion of the passageway 150 defines a dimension 605 and a dimension 610 that is perpendicular to the dimension 605. A second portion that is associated with the degradable metal body 165 defines a dimension 615 and a dimension 620 that is perpendicular to the dimension 615. As illustrated, the dimension 615 is greater than the dimension 605 while the dimension 620 is less than the dimension 610.

[0026] A similar method is used to seal the interior passageway 170 of the shunt tube 155. While only one degradable metal body 170 is shown associated with the shunt tube 155, any number of degradable metal bodies can be spaced along the shunt tube 155. While the method 500 is described as sealing an interior passageway 150 of the shunt tube 145, a similar method can be implemented to seal a downhole passageway when the degradable metal body 165 is in fluid communication with the downhole passageway. For example, and in some embodiments, the downhole passageway is defined between an interior surface of a casing or open-hole wellbore and an outer diameter of the lower completion assembly 85. The degradable metal body 165 at partially forms the outer diameter of the lower completion assembly 85 and is in fluid communication with the downhole passageway. In some embodiments, this method includes positioning the proppant 540 within the downhole passageway, corroding the degradable metal body 165 to produce metal particles; and creating the metal plug 525 in the downhole passageway. Often, the metal plug 525 includes the metal particles 530 and the proppant 535. However, the metal plug 525 is annular shaped to extend around the lower completion assembly 85. In this instance, the degradable metal body 165 is activated to fluidically seal an annulus formed between the outer diameter of the lower completion assembly 85 and the interior surface of the casing or open-hole wellbore.

[0027] In an example embodiment, during the operation of the assembly 85 and/or the execution of the disclosed methods, the degradation of a metal or a metal oxide is used to create a seal in the shunt tube 145 and/or within an annulus formed between outer diameter of the lower completion assembly 85 and the interior surface of the casing or open-hole wellbore. The degradable metal body 165 is a metal -based closure for shunt tubes that allows for closing the shunt tube without needing to provide operator action. The plug 525 provides blockage even in a gravel-filled shunt tube 145, in a partially gravel-filled shunt tube 145, as well as in an empty shunt tube 145. The plug 525 provides a blockage in a horizontally-oriented shunt tube 145 and in a vertically-oriented shunt tube 145. Moreover, the operation of the assembly 85 and/or the execution of at least a portion of the disclosed method results in a conformable metal-to-metal seal in a shunt tube 145 (or at least a metal-to-metal hydroxide seal). In some embodiments, the corrosive fluid is a high salinity brine at a high temperature, which are environments in which swellable rubbers are least effective. Moreover, the operation of the assembly 85 and/or the execution of at least a portion of the disclosed methods creates a seal in a gravel pack, without needing to pump two-part sealants.

[0028] Thus, a method of sealing an interior passageway of a shunt tube that forms a portion of a completion assembly has been described. Embodiments of the method may generally include positioning the completion assembly within a wellbore, wherein the completion assembly includes the shunt tube; and a degradable metal body associated with the shunt tube; performing, using the completion assembly, gravel packing operations; and permitting the degradable metal body to corrode so that the degradable metal body produces particles comprising a metal element and so that a plug is formed within the interior passageway of the shunt tube, wherein the plug comprises the particles. Any of the foregoing embodiments may include any one of the following elements, alone or in combination with each other:

The degradable metal body forms a portion of the interior passageway of the shunt tube.

The shunt tube is a perforated shunt tube.

The degradable metal body at least partially surrounds the shunt tube and downhole fluids are in contact with the degradable metal body via the perforations of the shunt tube.

The plug further comprises proppant from the gravel packing operations.

The degradable metal body comprises magnesium and/or aluminum.

Permitting the degradable metal body to corrode comprises exposing the degradable metal body to a corrosive fluid. The material comprising the degradable metal body is determined based on the size of the proppant.

[0029] Thus, a method of sealing a downhole passageway that is at least partially formed by a degradable metal body has been described. Embodiments of the method may generally include positioning the degradable metal body in a wellbore; permitting the degradable metal body to corrode to produce particles comprising a metal element; and permitting a plug to form in the downhole passageway, wherein the plug comprises the particles. Any of the foregoing embodiments may include any one of the following elements, alone or in combination with each other:

Positioning a proppant within the downhole passageway.

The plug further comprises a portion of the proppant.

The downhole passageway is an interior passageway formed within a perforated shunt tube and the degradable metal body at least partially surrounds the perforated shunt tube.

The downhole passageway is an interior passageway formed within a shunt tube and the degradable metal body at least partially defines a portion of the interior passageway of the shunt tube.

The downhole passageway is defined between an interior surface of the wellbore and an outer diameter of a lower completion assembly; and wherein the degradable metal body at least partially forms the outer diameter of the lower completion assembly.

The material comprising the degradable metal body is determined based on the size of the proppant.

The degradable metal body comprises magnesium. [0030] Thus, a completion assembly has been described. Embodiments of the assembly may generally include a shunt tube defining an interior passageway; and a degradable metal body associated with the interior passageway; wherein the degradable metal body is configured to corrode to release particles comprising a metal element so that a plug is formed within the interior passageway. Any of the foregoing embodiments may include any one of the following elements, alone or in combination with each other:

The shunt tube is a perforated shunt tube and the degradable metal body at least partially surrounds the perforated shunt tube.

The degradable metal body forms at least a portion of an interior surface of the shunt tube to define a portion of the interior passageway.

The degradable metal body comprises magnesium.

The plug further comprises a proppant.

The plug is a metal-to-metal hydroxide seal.

[0031] The foregoing description and figures are not drawn to scale, but rather are illustrated to describe various embodiments of the present disclosure in simplistic form. Although various embodiments and methods have been shown and described, the disclosure is not limited to such embodiments and methods and will be understood to include all modifications and variations as would be apparent to one skilled in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Accordingly, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.

[0032] In several example embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures could also be performed in different orders, simultaneously and/or sequentially. In several example embodiments, the steps, processes and/or procedures could be merged into one or more steps, processes and/or procedures.

[0033] It is understood that variations may be made in the foregoing without departing from the scope of the disclosure. Furthermore, the elements and teachings of the various illustrative example embodiments may be combined in whole or in part in some or all of the illustrative example embodiments. In addition, one or more of the elements and teachings of the various illustrative example embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.

[0034] In several example embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.

[0035] Although several example embodiments have been described in detail above, the embodiments described are example only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the example embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.

[0036] Illustrative embodiments and related methods of the present disclosure are described below as they might be employed in a pressure actuated inflow control device. In the interest of clarity, not all features of an actual implementation or method are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Further aspects and advantages of the various embodiments and related methods of the disclosure will become apparent from consideration of the following description and drawings.

Claims

CLAIMS WHAT IS CLAIMED IS:

1. A method of sealing an interior passageway of a shunt tube that forms a portion of a completion assembly, the method comprising:

positioning the lower completion assembly within a wellbore, wherein the completion assembly comprises:

the shunt tube; and

a degradable metal body associated with the shunt tube;

performing, using the completion assembly, gravel packing operations; and

permitting the degradable metal body to corrode so that the degradable metal body

produces particles comprising a metal element and so that a plug is formed within the interior passageway of the shunt tube, wherein the plug comprises the particles.

2. The method of claim 1, wherein the degradable metal body forms a portion of the interior passageway of the shunt tube.

3. The method of claim 1, wherein the shunt tube is a perforated shunt tube; and wherein the degradable metal body at least partially surrounds the shunt tube and downhole fluids are in contact with the degradable metal body via the perforations of the shunt tube.

4. The method of claim 1, wherein the plug further comprises proppant from the gravel packing operations.

5. The method of claim 1, wherein the degradable metal body comprises magnesium and/or aluminum.

6. The method of claim 1, wherein permitting the degradable metal body to corrode

comprises exposing the degradable metal body to a corrosive fluid.

7. The method of claim 4, wherein the material comprising the degradable metal body is determined based on the size of the proppant.

8. A method of sealing a downhole passageway that is at least partially formed by a

degradable metal body, the method comprising:

positioning the degradable metal body in a wellbore;

permitting the degradable metal body to corrode to produce particles that comprise a metal element; and

permitting a plug to form in the downhole passageway, wherein the plug comprises the particles.

9. The method of claim 8, wherein the method further comprises positioning a proppant within the downhole passageway; and wherein the plug further comprises a portion of the proppant.

10. The method of claim 8, wherein the downhole passageway is an interior passageway formed within a perforated shunt tube and the degradable metal body at least partially surrounds the perforated shunt tube.

11. The method of claim 8, wherein the downhole passageway is an interior passageway formed within a shunt tube and the degradable metal body at least partially defines a portion of the interior passageway of the shunt tube.

12. The method of claim 8, wherein the downhole passageway is defined between an interior surface of the wellbore and an outer diameter of a completion assembly; and wherein the degradable metal body at least partially forms the outer diameter of the completion assembly.

13. The method of claim 9, wherein the material comprising the degradable metal body is determined based on the size of the proppant.

14. The method of claim 8, wherein the degradable metal body comprises magnesium.

15. A completion assembly, comprising:

a shunt tube defining an interior passageway; and

a degradable metal body associated with the interior passageway;

wherein the degradable metal body is configured to corrode to release particles

comprising a metal element so that a plug is formed within the interior passageway.

16. The completion assembly of claim 15, wherein the shunt tube is a perforated shunt tube and the degradable metal body at least partially surrounds the perforated shunt tube.

17. The completion assembly of claim 15, wherein the degradable metal body forms at least a portion of an interior surface of the shunt tube to define a portion of the interior passageway.

18. The completion assembly of claim 15, wherein the degradable metal body comprises magnesium.

19. The completion assembly of claim 15, wherein the plug further comprises a proppant.

20. The completion assembly of claim 15, wherein the plug is a metal -to-metal hydroxide seal.