Note: Descriptions are shown in the official language in which they were submitted.
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$HApEo CHARGE ASSEMBLY, EXPLOSIVE UNITS, AND METHODS
FOR SELECTIVELY EXPANDING WALL OF A TUBULAR
CROSS .REFERENCE .To RELATED APPLICATIONS
W011 The present application is a Patent cooperation Treaty (PCT) application
that claims
priority to, and the benefit of, U.S. Patent Application No. 17/126,982, filed
on December 18,
2020 as a continuation-in-patt of UpS. Patent Application No. 16/970,602,
filed on August '17,
2020, 'which is a national phase of International PCT Application No,
PC112019/046920,
filed on August 16, 2019, which claims priority to U,S, Provisional PtOcnt
Application No,
62/76408, filed on August 16, 2018, with all prior applications, as set forth
above, having
the title of "Shaped Charge Assembly, Explosive Units, and Methods for
Selectively
Eipanding Wall of a Tubular.- The contents of the prior applications are
hereby incorporated
by reference herein in their entireties,
FIELD OF THE INVENTION
[00021 Embodiments of the present invention relate, generally, to shaped
charge tools for
selectively expanding a wail of tubular goods including, but not limited to,
pipe, tube, casing
and/or easing liner, in order to compress micro annulus pores and reduce micro
annulus leaks,
collapse open channels in a cemented annulus, and minimize other inconstancies
or defects in
the cemented annulus. The present disclosure also relates to methods of
selectively expanding
a wall of tubular goods to compress micro annulus pores and reduce micro
annulus leaks,
collapse open channels in a cemented annulus, and minimize other inconstancies
or defects in
the cemented annulus, The present disclosure further relates to a set of
explosive units that
may be used in:shaped charge: tools.
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BACKOROUND
[0003] Pumping cement into a wellbore may be part of a process of preparing a
well for
further drilling, production or abandonment The cement is intended to proteet
and seal
tubulars in the WellbOre,:c:etnenting s COMITIOWOW1 to permanently shut off
water and gas
Migration into the well. As part of the completion process of a prospective
production well:,
cement may be used to seal an annulus after a casing string has been run in
the wellbore.
Additionally, cementing may be used to seal a lost circulation zone, or an
area where there is
a reduction or absence of flow within the well. Cementing is used to plug a
section of an
eNisting well, in order to run a deviated Well from that point Also, cementing
may be used to
seal off all leak paths from the earth's downhole strata to the surface in
plug and
abandonment operations, at the end of the Weirs %eh! life.
[0004] Cementing is performed when a cement slurry :is pumped into the well,
displacing the
drilling fluids still located within the well, and replacing them with cement.
The cement
shiny floW$ to the bottom of the wellbore through the casing_ :frOm there, the
cement fillS in
the annulus between the casing and the actual weilbore, and hardens. This
et:WO a seal
intended to impede outside materials from entering the Well, in addition to
permanently
positioning the casing in place. The casing and cement once cured, helps
maintain the
integrity of the wellbore.
[0005_1 Although the cement material is intended to fOrm a Water tight seal
for preventing
outside materials and fluids florn entering the Wellbore, the cement material
is generally
porous and, over time, these outside materials and fluids can seep into the
micro pores of the
cement and cause cracks, micro annulus leak paths, decay andlOr contamination
of the
cement material. and the wellbore. Further, the cement in the cemented annulus
may
inadvertently include open: channels, sometimes referred to as "channel
columns" that
undesirably allow gas and/or fluids to flow through the channels, thus raising
the HSI( of
crackk det ay and/or contamination of the cement and wellbore. In other
situations, the
cement may :inadvertently not be provided around the entire 360 degree
circumference of the
casing,. This May occur especially in horizontal wells, Where gravity acts on
the cement above
the caSing:in the hOritontal wellbore. Further, Shifts in the Strata
(formation) of the earth may
canse Cracks in the cement, resulting in "channel columns" in the cement where
annulus flow
would otherwise not occur. Other inconsistencies or defects of the atpent. in
the annulus may
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arise from inconsistent viscosity of the cement, oci,ipf from a pressure
differential in the
formation that causes the cement lobe iticoeli!*tit in different areas of the
annulus.
[0006] Therefore, a need exists for systems and methods that are usable to
effectively reduce
andlor compress micro annulus pores in the cement or other seaiing materials
for minim4ingõ
Or eliminating the fOrmation craCks, initto annulus 10*, decay and/or
contamination of
the cement and wellbore..
[0007] in addition, a need exists for cost effective :systems and methods that
are usable to
selectively expand a wall or portion of a. wall of tubular gOods to compress
micro annulus
pores and reduce or eliminate micro annulus leaks.
[0008] A further need exists for Systems and methods that selectively expand
a. wall or
portion of a wall of tubular goods to effectively collapse and/or compress
open channels in a
cemented annulus, and/or compress the cemented annulus to cure other defects
or
inconsistencies in the cement to minimize or eliminate the unintended flow of
gas and/or
fluids through the cemented annuls.
[0009] The embodiments of the present invention meet all of these needs.
SUMMARY
[0010] At Set forth above, because cement material can be porous, Water, gas,
or Other
outside materials may eventually seep into the micro pores of the cement, and
penetrate
through the hardened concrete seal. The seepage, when driven by hydrostatic
formation
pressure, May Cause cracks, micro annulus leak paths from downhole to surface,
decay and/or
contamination of the cement, casing and weilbore, And, the cemented annulus
may
inadvertently include open channels (e.A., "channel columns") that allow gas
and/or fluids to
flow through the channels, Furthermore, the cement: may inadvertently .riot be
provided
around the entire circumference of the casing, and may have other
inconsistencies or defects
due to inconsistent viscosity of the cement, and/or a pressure differential in
the formation that
causes the cement to be inconsistent in different areas of the annulus.
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[00111 in view of the foregoing, an object of the present disclosure is to
provide tools and
methods that compress Micro annulus pores in cement to further reStrittiseal
off micro
annulus leaks migrating up a cement column in a well bore to conform to
industry and/or
regulatory standards. Compressing the cement reduces the porosity of the
cement by reducing
the number of micro annulus pores. The reduced number of micro annulus pores
reduces the
risk of seepage into the cement as well as the formation of micro annulus leak
paths. Another
object of the present disclosure is to provide tools and methods that eflectiv-
ely collapse
and/or compress open channels in a cemented annulus, and/or that effectively
compress the
cemented annulus to cure other defects or inconsistencies in the cement that
would otherwise
allow unintended flow of gas and/or fluids through the cemented annuls.
Generally, all
deleterious flow through the cemented annulus Caused by the above situations
may be
referred to as 41111111US flow, and the disclosure herein discusses apparatus
and methods for
reducing or eliminating annulus flow.
[00121 Explosive, mechanical, chemical or thermite cutting devices have been
used in the
petroleum drilling and exploration industry to clearlly sever a joint of
tithing or casing deeply
within a welibote. Such devices are typically Conveyed into a well for
detonation on a
wireline or length of coiled tubing. The devices may also be pumped downhole.
:Known
shaped charge explosive cutters include a consolidated amount of explosive
material having
an external surface dad with a thin metal liner. When detonated at the axial
center of the
packed material, at explosive shock wave, which may have a pressure force as
high as
3,000,000 psi, can advance radially along a plane against the tiller to
fluidize the liner and
drive the fluidized liner lineally and radially outward against the
surrounding pipe. The
fluidized liner forms a jet that hydro-dynamically cuts through and severs the
pipe. Typically,
the diameter of the jet may be around 5 to 10 mm.
[0013] The inventor of the present application has determined that, in some
cases, removing
the liner from the explosive material reduces the focus of the explosive shock
Wave So that
the wall of a pipe or other tubular member is not penetrated or SeVered.
Instead, the explosive
shock wave results in a selective, controlled expansion of the wall of the
pipe or other tubular
member. The liner-less shaped charge has a highly focused explosive wave front
where the
tubular expansion may be limited to a length of about 10.16 Centimeters (4
inches) along the
outside diameter of the pipe or other tubular member. Too much explosive
material, even
without a liner, may still penetrate the pipe or other tubular member. On the
other hand, toe
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little 00.10,51V* material may not expand the pipe or other tubular member
enough to achieve
its intended effeet. Selective expansion of the pipe or other tubular member
at strategic
locations along the length thereof can compress the cement that is set in an
annulus adjacent
the wall of the pipe or other tubular member, Or of the wellbore, beneficially
reducing the
porosity of the cement by reducing the number of micro annulus pores, and thus
the
associated tiSk of :micro annulus leaks. The expanded wall of the pipe or
other tubular
member, along with the compressed cement, forms a barrier The expanded wail of
the pipe
or other tubular member May also collapse and/or compress open channels in a
cemented
annulus, and/or may compress the cemented ZIMMIUS to cure other defects or
inconsistencies
in the cement (such as due to inconsistent viscosity of the cement, and/or a
pressure
differential in the formation).
[0014] One embodiment of the disclosure relates to a shaped charge assembly
for selectively
expanding at least a portion of a wall of a tubular. The shaped charge
assembly may
comprise: a housing comprising an outer surface facing away from the housing
and an inner
surface facing an interior of the h04,441g; a first explosive unit and a
second explosive unit,
Wherein each of the first explosive unit and the second explosive unit
comprises an explosive
material, wherein each of the first eXploSive unit and the second explosive
unit comprises
liner facing the inner surface of the housing. The density of the liner i or
can be, 6 gicc or
less, and the liner is, or can be, less ductal than copper, nickel, zinc, zinc
alloy, iron, tin,
bismuth, and tungsten. In this embodiment, the liner is configured to cause
the first explosive
unit and the second explosive unit, upon ignition, to expand, without
puncturing, said at least
a portion of the wall of the tubular to form a protrusion extending outward
into an annulus
adjacent the wall of the tubular.
[0015] in an embodiment, the liner may be formed of a glass material.
[0016] in an embodiment, the liner may be firmed of a plastic material,
[00171 In an embodiment, the liner may be perforated.
[0018] In an embodiment, each of the. first explosive unit and the second
explosive unit may
be geoinetrically symmetrical about an axis of reyO1utio0,
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[0019) In an embodiment, the density of the liner may be as.yrametric around
at least one of
the fist explosive unit and the second explosie unit,
[0020] In an embodiment, the shaped charge assembly timber comprise: a first
backing
plate adjacent the first explosive unit,, a aecOnd backing plate adjacent the
second explosive
unit, en aperture extending along said axis
revolution from an outer stirface of the !fitst
backing plate to at least an inner surface of the second backing plate, and an
explosive
detonator positioned along said axis of revolution and externally of the first
backing plate.
[0021] Another embodiment Of the diselOtife relates to a shaped charge
assembly for
selectively expanding at least a portion of a Wall of a tubular. The shaped
charge assembly
may comprise a housing comprising an outer surface facing away from the
housing and an
inner surface facing an interior of the housing, a first explosive unit and a
second explosive
unit, 'Wherein each of the first explosive unit and the second explosive unit
comprises an
explosive material and a liner, and wherein each of the first exploSive unit
and the second
explosive unit comprise an exterior surthce facipt; the inner surface of the
housing, 'Me
exterior surface and the liner can have a generally hemispherical shape,
wherein the first
explosive unit and the second explosive unit cornpriS,e a predetermined amount
of explosive
sufficient to expand, without puncturing, said at least a portion of the wall
of the tubular to
form a protrusion extending outward into an annulus adjacent the wail of the
tubular,
[0022] in an embodiment, a jet formed by igniting the first explosive Unit and
the world
explosive unit may be less focused than a jet formed by igniting non-
hemispherical explosive
units.
[0023] In an embodiment, each of the first explosive unit and the second
explosive unit may
be ueometricalty symmetrical about an axis of evolution.
[0024) A further embodiment of the disclosure relates to a shaped charne
assembly for
selectively expanding at least a portion of a wall of a tubular. The shaped
charge assembly
can comprise: a housing comprising an outer surface facing away from the
housing and an
inner surface facing an interior of the houSirig; ft first exploSive unit and
a second explosive
unit. Wherein each of the: fi't.st explosive unit and the second explosive
unit comprises an
e4),ItiaiNt material and a liner facing the inner surface of the housing; and
an extraneous
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object located between the inner surface of the housing and the liner of 'lot
explosive unit
and the Second explosive unit, wherein the extraneous object fouls a jet
formed by igniting
the first explosive unit and the second explosive unit, so that the jet
expands, without
puncturing Said at least a portion of the wall of the tubular to form a
protrusion extending
outward into an annulus adjacent the Wall of the tubular.
[00251 In an embodiment, the extraneous object may be one of a foam object, a
rubber
object, a wood object, and a liquid object.
[00261 In an embodiment,: each of the first eXplosive unit and the second
explosive unit may
be geotnetrically symmetical about an axis of revolution.
[00271 A further embodiment of the disclosure relates to a shaped charge
assembly for
selectively expanding at least a portion of a wall of a tubular, in this
embodiment, the shaped
charge assembly comprises: a housing comprising an outer surface facing away
from the
housing and an opposing inner surface facing an interior of the housing; a
first explosive unit
and a second explosive unit, wherein the fipt otplosive unit Comprises an
explosive material
formed adjacent a first ZifiC zinc alloy backing plateõ wherein the second
explosive unit
comprises an explosive material formed adjacent to a second zinc or zinc alloy
backing plate;
and an aperture extending along said axis from an outer surface of the first
zinc or zinc alloy
backing plate to at least an inner surface of the second zinc or zinc alloy
hacking plate. The
first explosive unit and the second explosive unit comprise a predetermined
amount of
explosive sufficient to expand, without puncturing, said at least a portion of
the wail of the
tubular to form a protrusion extending outward into an annulus adjacent the
wall of the
tubular.
[00281 In an embodiment, the housing may be fordied of a zinc Or zinc alloy
Material.
[00291 in an embodiment, the shaped charge assembly further comprises an
explosive
detonator positioned along said axis adjacent to, and externally of, the first
zinc or zinc alloy
backing plate,
[00301 In an embodiment, each of the first backing plate and the second
hacking plate
comprises an external surface opposite from said explosive material and
peipendicular to said
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axts Of reN.,olution, 40 wherein the external surlace Of at least one of the
first .4.inc or 40c.
alloy baCking .plate and the second zinc or .zinc alloy backlog plate has a
plurality of blind
pockets therein distributed, in a .pattern about said axis of revolution.
[00311 In an embodiment, each of the first explosi'e. unit and the second
explosive unit may
be symmetrical about an axis of revolution.
[0032] Another embodiment of the disclosure relates to a method of reducing a
leak in an
annulus adjacent an outer surface of a tubular in a wellboreõ the method
comprising: inserting
a plug into the tubular, and positioning an expansion tool Within the tubular
at a Ideation
uphole ..of the plug, wherein the -expansion tool contains an anlount of
explosive material
based at least in part on a hydrostatic pressure bearing on the tubular, the
'amount of explosive
material for producing an .expiOsive: forcee-sufficient to expand, without
puncturing, the wall
of the tabtflar. The method steps continue by actuating the expansion tool to
expand the wall
of the tubular radially outward., without perforating or cutting through the
wall of the tubular,
to tbrm a protrusion that extends into the annulus adjacent the outer surface
of the wall of the
tubular, wherein the protrusion seals the leak in the annular,
[00331 in an enibodimentõ the method further compris.es actuating one or more
puncher
charges in the tubular to punch holes in the wall of the tubular at a ideation
uphole of the
plug; mid providing a sealant into the annulus through the holes in the wall
of the tubular..
[00141 A further embodiment of the disclOsthe relates to a method of
selectively expanding
walls of two concentric tubulars comprising an inner tubular and an outer
tubular. The
method can comprise the steps. of: positioning an expansion tool within the
inner tubular,
Wherein the expansion toot can contain an amount of explosive material, which
is based at
least. in part on .a hydrostatic pressure bearing on at. least the inner
tubular and the outer
tubular, and the amount of exOlOsiVe .marterial -produces an explosive forte
suflieient to
expand, without puncturing, a wall of the inner tubular and a wall of the
outer tubular, The
method .steps can continue by actuating: the expansion tool once to expand
both the wall of
the inner nibular and. the wall of the outer tubular =radially outward.,
without perforating or
cutting through the wall of the inner tubular and the wall of the outer
tubular, to form
protrusion of the wall-af the inner tubular that extends intC) an annulus
between the inner
tubular and the outer tubular, and to forth a concentric protrusion of the
wall of the outer
tubular into an amiulus adjacent the outer surface of the wall of the outer
tubular.
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[0035] Another embodiment of the disclosure relates to a method of selectively
expanding a
wall of a tubular comprising a central bore. The method can comprise the steps
of:
positioning an expansion tool within the tubular, wherein the =expansion tool
can contain an
amount of explosive material for producing an explosive force sufficient to
expand, without
puncturing, the wall of the tubular; and actuating the expansion tool to
expand the wall of the
tubular radially outward, without perforatin or cutting through the wall of
the tubular, to
fk.vm a protrusion that extends outward from the central bore of the tubular.
The steps of the
method can conclude by inserting the selectively expanded tubular into a
wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Various embodiments are hereafter described in detail and with
reference to the
drawings wherein like reference characters designate like or similar elements
throughout the
several figures and views that collectively comprise the drawing&
[00371 FIG. 1 is a cross-section of an embodiment of a tool, including a
shaped charge
assembly. IN- selectively expanding at least a portion of a wall of a tubular,
[ÃO38] FIG. 2A to FIG. 2F illustrate methods. of selectively expanding at
least a portion of
the w1l of a tubular using the tool.
[0039] FIG: 2G -to FIG. 21 illustrate embodiments of a tool that may be used
in some of the
methods illustrated in FIG. 2A to FIG. 2F,
[0040S1 FIGS, 21 to 2L illustrate methods of selectively expanding at least a
portion of the
wall of a tubular surround by formation,
[0041] FIGS. 2N-1 and 2N illustrate a method of selectively expanding the
wails of two
concentric tubular&
[0042] FIG. 3A and FIG, 3B illustrate graphs showing swell profiles resulting
from tests of a
pipe and an outer housing,
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[0043] FIG, 4 is a crosS-section of m1 ernbodiment of the tool, including a
shaped charge
assembly,
[0044] FIG. 5 is a cross-section of an embodiment of the tool, including a
shaped charge
assembly.
[0045] FIG. 6 is a cross4Oction of an embodiment of the tool, including a
shaped charge
assembly,
[0046] FIG, 7 it a plan view of an embodiment of an end plate showing marker
pocket
borings,
[0047] FIG. a is a cross-section view of an embodiment of an end plate along
plane 84 Of
Fla 7,
[0048] FIG, 9 is a bottom plan view of an embodiment of a top sub after
detonation of the
explosive material.
[0049] FIG. 10 illustrates an embodiment of a set of explosive units.
[0050] FIG: I illustrates a perspective view of exptpsive units in the set,
[0051] FIG. 12 shows a plan form view:of an explosive unit in the set.
[0052] [0039] FIG.....3 shows a: plant:ban view of an alternative embodiment
of an explosive
unit in the set.
[0053] FigS, 14-17 illustrate another embodiment of an exploSive unit that may
be included in
a set of several similar units.
[0054] FIG, 18 illustrates an embodiment of a centralizer assembly.
[0055] FIG. 19 illustrates an alternative embodiment of a centralizer
assembly.
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[0056] FIG. 20 illusfrates another embodiment of a centralizer assembly.
[0057] FIGS. 21 and 22 illustrate a further embodiment of a centralizer
assembly.
[0058] FIG. 23 is a cross-section of another erribodiment of a tool:.
including a shaped charge
=assembly, for selectively expanding at least a portion of a wall of a
tubular.
[0059] FIG, 24 is a cross-section of further embodiment of a tool, including a
shaped charge
assembly, for selectively expanding at least a portion of a wall of a tubular,
[0060] FK1. 25 is a cross-section of further embodiment of a toot, including a
shaped charge
assembly, for selectively expanding at least a portion of a wall of a tubular,
[0061] FIGS. 26A-26D illustrate a method of reducing an annulus leak in a
wellbore,
according to an embodiment.
[0062] FIGS, 27A-27E illustrate another method of reducing an annulus leak in
a wellbore,
according to an embodiment
[0063] FIG 28 is a cross-section of an embodiment of a dual firing end
explosive column
tool, as assembled for operation, for selectively expanding at least a portion
of a wall of a
tubular.
[0064] FIG. 29 is an enlargement of Detail A in FIG. 28.
[0065] FIG. 30 is an enlargement of Detail B in FIG. 28.
[0066] FIG. 31 is a cross-section of an embodiment of a dual end firing
explosive column
tool, as assembled for operation, for selectively expanding at least a portion
of a wall of a
tubular.
[0067] FIG, 32 is an enlargement of Detail A in FIG. 31,
[0068] FIG. 33 is an enlargement of Detail 13 in FIG. 31,
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[0069] FIGS, 34A: to 34c illustrate a method of selectively expanding at least
a portion of the
wall of a -tubular Using the dual end firing explosive cOlumn toOL
DETAILED DESCRIPTION OF THE INVENTION
[0070] Before explaining the disclosed embodiments in detail, it is to be
understood that the
present disclosure is not limited to the particular embodiments depicted or
described, and that
the invention can be practiced or carried out in various ways. The disclosure
and description
herein are illustrative and explanatory of one or more presently preferred
embodiments and
variations thereof, and it will be appreciated by those skilled in the art
that various changes in
the design, organization, riWarts of operation, strnetures and location,
methodology, and use
of mechanical equivalents 'Maybe made Without departing from the spirit of the
invention,
[0071] As well, it should be understood that the drawings are intended to
illustrate and
plainly disclose presently preferred embodiments to one of skill in the art.,
but are not
intended to be manufacturiniz level drawings or renditions of final prodiacts
and may include
simplified conceptual views to facilitate understanding or 04lanation.
Further, the relative
skit and arrangement of the components May differ from that shown and still
operate within
the spirit of the invention.
[0072] Moreover, as used herein, the terms 'pp:" and "down", "upper" and
"lower",
"upwardly" and downwardly". "upstream" and "downstream" ; "above" and "below"
and
other like terms indicating relative positions above or below a given point or
element are used
in this description to more clearly describe some. embodiments discussed
herein. However,
when applied to equipment and methods for use in wells that are deviated or
horizontal, such
terms may refer to a left to right, right to left, or other relationship as
appropriate In the
specification and appended claims, the :terms "pipe", "tube", "tubular",
"casing" andior 'other
tubular goods" are to be interpreted and defined generically to Mean any and
all of such
elements without limitation of industry usage. Because many varying and
different
embodiments may be made Within the scope of the concept(s) herein taught, and
because
many modifications may be made in the embodiments described herein, it is to
be understood
that the details herein are to be interpreted as illustrative and
nowlitniting,
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100731 fl:(3. 1 shows tool 10 for Selectively expanding at least a portion of
a wall of a
tubular, The tool 10 compriSeS a top sub 12 having a threaded internal socket
14 that axially
penetrates the "upper" end of the top sub 12. The socket thread 14 prOvides a
secure
mechanism for attaching the tool 10 with an appropriate wire line or tubing
suspension string
(not $1)004 PIO tool 10 can have a substantially Circular cross,section, and
the outer
cOnfiguration of the tool 10 can be substantially cylindrical, The "lower" end
of the top sub
12, as shown, can include a substantially flat end thee 15. As shown, the flat
end face 15
perimeter of the top sub can be delineated by an assembly thread 16 and an 0-
ring seal 18.
The axial center 13 of the top sub 12 can be bored between the assembly socket
thread 14 and
the end face 1:5 to provide a. socket 30 for an explosive detonator. 31. In
some enthodiments,
the detonator May comprise a bi-directional booster With a detonation cord.
[0074] A housing 20 don be secured to the top sub 12 by; Ar example, an
internally threaded
houSing sleeve 22. The 0-ring /8 can seal the interface from fluid invasion of
the interior
housing volume.. A window section 24 of the housing interior is an inside wall
portion of the
housing 20 that bounds a cavity 25 around the shaped charge between the outer
or base
perimeters 52 440 54, In an embodiment, the upper and lower limits of the
window 24 are
coordinated with the shaped charge dimensions to place the window 'sills" At
the
approximate mid-line between the inner and outer surfaces of the ejcplOSi've
material 60. The
housing 20 may be a frangible steel material of approximately 55-60 RoCkWell.
"C" hardness.
[0075] As shown, below the :window :24, the *Ong 20 can be internally
terminated by an
integral end wall 32 having a substantially flat. internal end-face 33. The
external end-face 34
of the end Wall may he frusto-conical about a central end boss 36. A hardened
steel
centralizer assembly 38 can be secured to the end boss by assembly bolts 39a,
39b, wherein
each blade of the centralizer assembly 38 i5 secured with a respective one of
the assembly
bolts:39a, 39h (ie.., each blade has its own assembly bolt).
[0076] A shaped charge assembly 40 can be spaced between the top sub end face
1.5 and the
internal end-lice 33 of the housing 20 by a pair Of resilient, eleettically
non-conductiVe, ring
spacers 56 and 58. In some embodiments, the ring spacers may comprise silicone
sponge
washers. An air space of at least 0.25 centimeters (0.1 inches) is preferred
between the top
sub end face 15 and the adjacent face of a thrust disc 46. Similarly, a
resilient, non-
conductive lower ring spacer 58 (or silicone sponge Washer) provides an air
spec that can be.,
13
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WO 2022/150175 PCT/US2021/064072
at W.4 0..25 Centimeters (0:1 inches) between the internal end-face 33 and an
adjacent
assembly lower end plate 48.
[0077] Loose explosive partieles cm be ignited by impact or friction M
handling, bumping or
dtripping the assembly: Ignition that is capable of propagating a premature
explosion may
occur at contact points between a steelõ shaped charge thrust disc 46 or end
plate 48 and a
steel housing 20, To minimize such ignition opportunities, the thrust disc 46
and lower end
plate 48 can be fabricated of non-sparking brass. In an embodiment, the thrust
disc 46 and
lower end plate 48 may be formed of zinc, Or a zinc alloy material. For
instance, the thrust
disc 4 and lower end plate 48 may be formed of zinc powder or powder
including zinc,
UpOn detonation of the explosive Material 60, the Zinc is cOnsumed by the
resulting eXplOsion
such that there is very little, if any, debris left over from the thrust disc
46 and lower end
plate 48* As a result, there maybe less debris in the well that could later
obstruct the naming
of other tools in the well. For the same reasons, i.e., to minimize the amount
of debris after
detonation of the explosive material 60, the housing 20 may also be formed of
zinc, or a zinc
alloy material,
[0078] The outer faces 91 and 93 of the end pates 46 (upper thrust disc or
back up plates)
and 483 as respectively shown by FIG. 1õ can be blind bored with marker
pockets 95 in a
prescribed pattern, such as a circle with uniform arcuate spacing between
adjacent pockets as
illustrated by FIGS. 7 and. The pockets 95 in the outer faces 91., 93 are
shallow surface
cavities that are stopped short of a complete aperture through the end plates
to form
selectively weakened areas of the end plates, When the explosive material 60
detonates, the
marker pocket walls are converted to jet material. The jet of fluidized end
plate material scar
the lower end face 15 of the top sub 1./ with impression marks =n a pattern
corresponding
to the original pockets as Shown by FIG, 9.. When the top sub 12 is retrieved
after detonation,
the uniformity and distribution of these iptpissitctt) marks 99 reveal, the
quality and
uniformity of the detonation and hence, the quality of the explosion. For
example, if the top
sub face 15 is marked with only a half section of the end plate pocket
pattern, it May be
reliability concluded that only half of the explosive material 60 correctly
detonated.
[0079] The explosive material 60 may be formed into explosive 'Units 60
explosive units
60 traditionally used in the composition a shaped charge tools comprises a
precisely
measured quantity of powdered, high explosive material, such as RDXõ TINS or
MIX: The
14
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O(Oiet*e: material. 60 may he formed into units 60 shaped as a truncated col*
by placing the
explOSive Material in a press Mold fixture. A .preeistly measured quantity of
powdered
explosive material, such as RDX, RN'S or MIX, is distributed within the
internal cavity of
the mold. Using a Central core post as a guide mandrel through an axial
aperture 47 in the
:upper thrust disc 46, the thrust disc is placed over the explosive powder
alid the assembly
subjected to a specified compression pressure This pressed lamination
comprises a half
section of the shaped charge assembly 40. The explosive units 60 may be
symmetric about a
longitudinal axis 13 extending through the units 60.
[0080] The lower half section of the shaped charge assembly 40 can be formed
in the same
Manner as described aboNie, having a central aperture 02 of about 0,3
centimeters
inches) diameter in axial alignment :with thrust disc aperture 47 and the end
plate aperture 49.
A complete assembly comprises the contiguous union t)f the lower and upper
half sections
along the juncture. plane 64. Notably, the thrust disc 46 and end plate 48 are
each fabricated
around respective annular boss sections 70 and 72 that provide a protective
material mass
between the respective apertures 47 and 49 and the explosive material 60.
These bosses are
terminated by distal end faces 71 and 73 within a critical initiation distance
of about 0A3
centimeters (0.05 inches) to about 0:25 .centimeters (0.1. inches) from the
assembly juncture
plane 64. The critical initiation distance may be increased or decreased
proportionally for
other sizes. Hence, the explosive material 60 is insulated from an iimition
wave issued by the
detonator 31 until the woe ain the prox,imity of the juncture plane 64.
[0081] The apertures 47, 49 and 62 for the FIG. I embodiment remain open and
free of
boosters or other explosive materials. Although an original explosive
initiation point for the
shaped charge assembly 40 only occurs between the boss end faces 71 and 73,
the original
detonation event is generated by the detonator 31 outside of the thrust disc
aperture 47. The
detonation 'woe can be channeled along the empty thrust disc aperture 47 to
the empty
central aperture 62 in the explosive material, Typie4y, An explosive load
quantity Of 38.8
grams (1,4 ounces) of HMX compressed to a loading pressure of 20,7 Mpa (3,000
psi) may
require a moderately large detonator 31 of 420 mg (0.02 ounces) HMX for
detonation.
[0082] The FIG. 1 embodiment obviates any possibility of oriewation error in
the field while
loading the housing 20. A detonation wave may be channeled along either boss
aperture 47 or
49 to the -kt-)losii,,,e material. 60 around the central aperture 62.
Regardless of which
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orientation the shaped charge assembly 40 is given when inserted in the
housing 20, the
detonator 31 will initiate the explosive material O.
[00831 In this embodiment, absent from the explosive material units 60 is a
liner that is
conventionally provided on the exterior surface of the explosive material and
used to cut
through the wall of a tubular. Instead, the exterior surface of the explosive
material is
exposed to the inner surface of the housing 20. Specifically, the housing 20
comprises an
outer surface 53 facing away from the housing 20, and an opposing inner
surfitce 51 facing an
illiefiOr of the housing 20. The explosive units 60 each comprise an exterior
surface 50 that
faces and is exposed to the inner surface 51 of the housing 20. Describing
that the exterior
surface SO of the explosive units 60 is ei(pm.3ed to the inner surface 51 of
the housing 20 is
meant to indicate that the exterior surface 50 of the explosive units 60 is
not provided with a
liner, as is the case in conventional cutting devices. The explosive units 60
can comprise a
predetermined amount of explosive material sufficient to expand at least a
portion of the wall
of the tubular into a protrusion extending outward into an annulus adjacent
the wall of the
tubular. 1'ot instance, testing conducted with a 72 grams (2.54 ounces) MIX,
6.8 centmeter
(2.7 inches) outer diameter expansion charge on a tubular having a 11A
centimeter (43 inch)
outer diameter and a 10.1 centimeter ('198 inch) inner diameter resulted in
expanding the
outer diameter of the tubular to 13,5 centimeters (532 inches), i.e expansion
was limited to
a 10,2 centimeter (4 inch) length along the outer diameter of the tubular. It
is important to
note that the expansion is a controlled outward expansion of the wall of the
tubular, and does
not cause puncturing, breaching, penetrating or severing' of the Wal I of the
tubular. The
annulus may be formed between an outer surface of the wall of the tubular
being expanded
and an inner wall of an adjacent tubular or a formation. Cement located in the
annulus is
compressed by the protrusion, reducing the porosity of the cement by reducing
the number of
micro annulus pores in the cement or other sealing agents. The reduced-
porosity cement
.provides a seal against moisture seepage that WOtild otherwise lead to
cracks, decay and/or
contamination of the cement, casing and wellbore. The compressed cement may
also collapse
and/or compress open channels in a cemented annulus, aridior may compress the
cemented
annulus to cure other defects or inconsistencies in the cement (such as due to
inconsistent
viscosity of the cement, and/or a pressure differential in the formation).
[00841 A method of selectively expanding at least a portion of the wall of a
tubular using the
tool 10 described herein may be as {-Mows. The tool 10 is assembled including
the housing
16
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20 containing explosive material 60 adjacent two end plates 46, 48 on opposite
sides of the
explOSive material 60, As discussed in the embodiment above, the housing 20
eompriks an
inner surface 51 facing an interior of the housing 20, and the explosive
material 60 comprises
an exterior surface 50 that faces the inner surface 51 of the housing 20 and
is exposed to the
inner surface 51 of the housing 20 (te there is to liner on the exterior
surface 50 of the
explosive material 60),
[0085] A detonator 31 (see Fig. 11) can be positioned adjacent to one of the
two end plates 40,
48, The tool 10 can then be positioned within an inner tubular Ti that is to
be expanded, as
shown in Fa 2A. The inner tubular T1 may be within an outer tubular T2, such
that an
annulti "A" eXists betWeen the outer diameter of the inner tubular TI and the
inner diameter
of the outer tubular TZ A sealant, such as eement "C" May be provided in the
annulus "A":
When the tool 10 reaches the desired location in the inner tubular T1, the
detonator 31 is
actuated to ignite the explosive material 60: causing a shock wave that
travels radially
outward to impact the inner tubular Ti at a first location and expand at least
a portion of the
Wall of the inner tubular Ti radially outward without perforating or putting
through the
portion of* wall, to form a protrusion "Pr of the inner tubular Ti at the
portion of the wail
as shown in FIG. 28. The protrusion '1?" extends into the annulus "A". The
protrusion "P"
compresses the cement "Cr to reduce the porosity of the cement by reducing the
number of
micro pores. The compressed cement is shown in FIG, 2B with the label "CC".
The reduced
number of micro pores it the compressed cement "CC" reduces the risk of
seepage into the
cement. FUrther, the protrusion '1'" creates a ledge or barrier that helps
seal that portion of the
wellbore from seepage of outside materials. Note that the pipe dimensions
shown in F [GS.
2A to 2F are exemplary and for context, and are not limiting to the scope of
the invention,
[0086) The protrusion "Pr may impact the inner wall of the outer tubular12
after detonation
of the explosive material 60, in some embodiments, :the protrusion 7" may
Maintain contact
with the inner wall of the outer tubular T2 after expansiOn :is complete, In
other embodiments,
there may be a, small space between the protrusion "P" and the inner wall of
the outer tubular
T2. For instance, the embodiment of Fig. 3B shows that the space. between the
protrusion
and the inner wall of the outer tubular T2 may be 0,07874 centimeters (0.0310
inches),
However, the size of the space will v4,ty depending on several factors,
including, but -not
limited to, the : ize thickness), strength and material of the inner
tubular TI. the type and
amount of the explosive material in the explosive units 60, the phygat profile
of the exterior
17
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SI:04e 50 of the explosive units 60; the hydrostatic pressure heating on the
inner tubular Ti
the desired size of the protrusion, and the nature Of the *tillbore operation:
The small space
between the protrusion "P" and the inner wall of the other tubular 12 may
still be effective
for blocking flow of cement, .barite, other sealing materials, drilling mud,
etc., so long is the
protrusion "P" approaches the inner diameter of the outer tubular T2. This is
because the
viscosity of those materials generally prevents seepage through such a small
space. That is,
the protrusion may form a choke that captures (restricts flow of) the
cement long enough
for the cement to set and form a seal. Expansion of the inner tubular Ti at
the protrusion "r
causes that portion of the wall of the inner tubular TI to be work-hardened,
resultinrz in
greater yield strength of the wall at the protrusion "P", The portion of the
wail haying the
protrusion "P" is not weakened. In particular, the yield strength of the inner
tubular 11
increases at the protrusion "F% while the tensile strength of the inner
tubular TI at the
protrusion 1)" decreases only nominally, Expansion of the inner tubular Ti at
the protrusion
"P" thus strengthens the tubular without breaching the inner tubular Ti.
[00871 The ;.p4nitude of the proU'usion in the embodiment discoed above
depends on
several factors, including the amount of explosive material in the explosive
units 69, the type
of explosive thaterialõ the physical profile of the exterior surface 50 of the
explosive units 60,
the strength of the inner tubular IL the thickness of the tubular wall, the
hydrostatic pressure
bearing on the inner tubular TI, and the clearance adjacent the tubular being
expanded, i.e.,
the width of the annulus 'A" adjacent the tubular that is to be epanded. In
the embodiment if
FIG. the physical profile of the exterior surface $0 of the explosive units 60
is Shaped as a
side-ways "V". The angle at which the legs of the "V" shape intersect each
other may be
varied to adjust the size andlor shape of the protrusion_ Generally, a smaller
angle will
generate a larger protrusion 'P", Alternatively, the physical profile of the
exterior surface 50
may he curved to define a generally hemispherical shape, such as shown in the
example of
HO_ 23, in that ernbodimeni, the exterior surface 50b of the explosive Ian* 60
is shaped*ith
a curve or curves, instead of the sideways "V' shape having, an intersection
at the
convergence of two linear lines as Shown in Figs. I, 2G, 2H, 21, 4-6, 24 and
25. As used
herein, the phrase "generally hemispherical shape' means that the exterior
surface 50 of the
explosive units 60 may have a perfect hemispherical shape, a flattened
hemispherical shape,
an oblong hemispherical, shape, or a shape formed only of curves or curved
lines. in some
embodiments, the "generally hemispherical shape" May also mean that the
exterior surface 59
of the exploSive units 60 may he composed of a series of three or more linear
lines that
18
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together -form a concave shape towards the cavity 25 around the shaped charge.
in further
embodiments, the "generally hemispherical shape' may include a sideways "U"
shape.
Generally speaking, the "generally hemispherical shape of the explosive units
60 results in
such explosive units 60 producing, upon ignition, a jet that is not as focused
as the "V" shape
explosive units 60. Accordingly, even. when the explosive units 60 having the
generally
hemispheric& exterior surface 50b include a liner, according to one embodiment
herein, the
shape of the exterior surface 50b may controlled so that the collapsed liner
fbrms a jet that is
not focused enough to penetrate the inner tubular Ti. That is, the generally
hemispherical
exterior surface 50b may be shaped, upon ignition of the explosive units 60,
to form the
protrusion P' discussed herein without puncturing the inner tubular T1.
[0088j The method of selectively expanding at least a ponion of the wall of a
tubular T1
using the shaped charge tool 10 described herein may be modified to include
determining the
folio win characteristics of the tubular Ti: a material of the tubular TI, a
thickness of a wall
of the tubular .1`1, an inner diameter of the tubular Ti., an outer diameter a
the tubular TI, a
hydrostatic pressure bearing on the tubtilar T1, and a size of a protrusion
"P" to be formed in
the wall of the tubular Ti. Next, the explosive force necessary to expand,
without puncturing,
the wall of the tubular Ti to tbrm the protrusion is
calculated, or determined via testing,
based on the above determined material characteristics. As discussed above,
the
determinations and calculation of the explosive force can be performed via a
software
program executed on a computer. Physical hydrostatic testing of the explosive
expansion
charges yields data which may be input to develop computer models. The
computer
implements a central processing unit (CPU) to execute steps of the program.
The program
may be recorded on a computer-readable recording medium, such as a CD-ROM, or
temporary storage device that is removably attached to the computer.
Alternatively, the
software program may be downloaded from a remote server and stored internally
on a
memory device inside the computer. Based on the necessary force, a requisite
amount of
explosive material for the one or more explosive material units 60 to be added
to the shaped
charge tool 10 is determined. The requisite amount of explosive material can
be determined
via the software program discussed above.
[0089j The one or more explosive material units 60, having the requisite
amount of explosive
material, is then added to the shaped charge tool 10. The loaded shaped charge
tool 10 is then
positioned within the tubular Ti at a desired location. Next, the shaped
charge to 10 is
19
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actuated to detonate the one or more explosive material units 60, resulting in
.a shock wave, as
discussed above, that expands the Wall of the tubular Ti radially:Outward,
without perforating
or cutting through the wall, to form the protrusion "P"_ The protrusion "P"
extends into the
annulus "k' adjacent an outer surface of the wall of the tubular TI.,
[0090] A first series of tests was conducted to compare the effects of sample
explosive units
60, which did not have a liner, with a comparative explosive unit that
included a conventional
liner on the exterior surface thereof The explosive units in the first series
had 15,88
centimeter (6_25 inch) outer housing diameter, and were each tested separately
in a respective
17,8 centimeter (7 inch) outer diameter test pipe, The test pipe had a .16
centimeter (63 inch)
inner diameter, and a 0,89 centimeter (0:35 inch) Wall Thickness, L80.
[0091] The comparative sample explosive unit had a 15.88 centimeter (&25 inch)
outside
housing diameter and included liners. Silicone caulk was added to foul the
liners, leaving
only the outer 0:76 centimeters (0.3 inches) of the liners exposed for
potential jetting. 77,6
grams (27 ounces) of fliN4X main explosive was used as the eztplosive
material. The sample
explosive unit had a 15:88 Centimeter (.6.25 inch) outside housing diameter
and was free
of any liners. 155.6 grams (5,5 ounces) of UNIX main eXplosiVt Was used as the
explosive
material. The sample "B" explosive unit had a 15:88 centimeter (6.25 inch)
outside housing
diameter and was free of any liners, 122,0 grams (43 ounces) of HMX main
explosive was
used as the explosive material.
[0092] The test was conducted at ambient temperature with the following
conditions.
Pressure: 20.7 Nipa (3)000 psi). fluid: water. centralized Shooting Clearance:
0.06
centimeters (0,03 inches), The Results are provided below in Table L
Table l
Test Summary in 17,8 centimeters (7 inch) 01). x 089 centimeters (0.350 ittb)
wail L-80
Main Load MIX Swell
Sample
(grams) (ounces) (centimeters) (inches)
Comparative (with liner) 77.6g 07) 18.5 cm (7.284 inches)
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PCT/US2021/064072
A 155.6 g (5.5 oz) 193
em(7,600 inches)
122.0 g (4.3 oz) 18.6
cm (7.317 inches)
[0093] The comparative sample explosive. ,unit produced an 18.5 centimeter
(718 inch) swell,
but the jetting caused by the explosive material and liners undesirably
penenated the inside
diameter of the test pipe. Samples "A" and "B" resulted in 193 Centimeter (74
inch) and
18.6 centimeter (732 inch) swells (protrusions), respectively, that svere
smooth and uniform
around the inner diameter of the test pipe.
[0094] A second test Wag performed using the Sample 'A" exploSi*e unit in a
test pipe
having similar properties as in the first series of tests, but this tin* with
an outer housing
outside the Wt. pipe to see how the character of the swell in the test pipe
Might change and
whether a seal could be elected between the test pipe and the outer housing.
The test pipe
had a 17.8 centimeter (7 inch) outer diameter, a 16,1 centimeter (632 inch)
inner diameter, a
0.86 centimeter (0.34 inch) wall thickness, and a 813,6 Mpa (118 KSI) tensile
strength. The
outer housing had an 21,6 centimeter (83 inch) outer diameter, 0. 18.9
centimeter (7.4 inch)
inner diameter, a 135 centimeter (9,53 inch) wall thickness., and a 723,95 MO
(105 KS1)
tensile strength.
[0095] The second test waS conducted at ambient temperature with the following
conditions.
Pressure: 20.7 Mpa (3,000 psi), Fluid: Water, Centralized Shooting Clearance',
0.09
centimeters (0,04 inches). Clearance between the 17.8 centimeter (7 inch)
outer diameter of
the test pipe and the inner diameter of the housing 0.55 centimeters (012
inches). After the
sample explosive unit was detonated, the swell on the 17,8 centimeter (7
ineh) test pipe
measured at 18,9 centimeters (7.441 inches) x 18.89 centimeters (7,44 inches),
indicating
that the inner diameter of the outer housing (18.88 centimeters (7.433
inches)) somewhat
retarded the swell (19,3 centimeters (7,6 inches)) observed in the first test
series involving
sample "A": There was thas "bounce back" oldie swell owed by the inner
diameter of the
outer housing. In addition, the inner diameter of outer housing increased from
18.88
centimeters (7,433 inches) to 18,98 centimeters (7,474 inobeS), The clearance
between the
Outer diameter of the test pipe and the inner diameter of the outer housing
was reduced from
035 centimeters (022 inches) to 0.08 centimeters (0,93 inches), FIG. 3A shows
a graph 400
illustrating the swell profiles of the test pipe and the outer housing. FIG
3:13 is a: graph 401
21
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illustrating an overlay of the swell profiles showing the 0,08 centimeter
(0,03 inch) resulting
clearance,
[0096] A second series of tests was performed to compare the performance of a
shaped
charge tool 10 (with liner-less explosive units 60) having different explosive
unit load
weights. In the second series of tests, the goal was to maximize the expansion
of a 17.8
centimeter (7 inch) outer diameter pipe having a wall thickness cif 1.37
centimeters (0.54
inches), to facilitate operations on a Shell North Sea Puffin well. Table 2
shows the results of
the rests.
Table 2
Centralized Shooting M.ax Swell of 7"
Explosive Unit Load Clearance 0.1).
Pipe
Test Explosive Weight
Weigh tit
175 g HMX =125 g 0.26 cm 18.8 cm
(4.4 oz,) (0.103 inches)
(7.38 inches)
217 g HMX 145g 0,26 ern 19.04 CM
(7.65 oz.) (5,11 oz.) (0,103 inches)
(7.49 inches)
350 g HMX 204 g 0.26 cm 20.2 cm
3
(12,35 oz.) (7,2 oz.) (0.103 inches)
(7.95 inches)
[00971 Tests #1 to #3 used the shaped charge tool 10 having liner-less
explosive units 60
with progressively increasing explosive weights. In those tests, the resulting
swell of the 17.8
centimeter (7 inch) outer diameter pipe continued to increase as the explosive
weight
increased. However, in test #3, which utilized 350 puns (12.35 ounces) SIMX
resulting in a
204 gram (7.2 ounces) -unit loading, the focused energy of the expansion
charged breached
the 17.8 centimeter (7 inch) outer diameter pipe. Thu, .to maximize the
expansion of this pipe
without breaching the pipe would require the amount of explosive energy in.
test #3 to be
delivered with less focus.
[0098] Returning to the method discussed above, the relatively short expansion
length (e.g.,
10,2 centimeters (4 inches)) may advantageously seal off micro annulus leaks
or cure the
22
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other cement defects :discussed herein, It may he the case that the cement
density between the
outer diameter of the inner tubular Ti and the inner diameter of the outer
tubular 12 was
inadequate to begin with, such that a barrier may not be formed and/or the
cement "C"
present between the inner tubular TI and the outer tubular T2 may simply be
forced above
and below the. expanded protrusion "P" (see, e49 Fig, 2C), While there may
still he a senti
compression "SC,' of the cement and reduction in porosity, it Might not be
adequate to: slow a
micro annulus leak in a manner that would contbrm to industry and/or
regulatory standards.
in such a case, instead of detonating just one explosive unit 60, multiple
explosive units 60
may be detonated, sequentially and in close proximity to each other, or
simultaneously and in
close proximity to each other, For example, if two explosive units 60 were
detonated
Sequentially or simultaneously, 10.16 centimeters (4,0 inches) apart in a *one
where there is
an inadequate cement job, the compression effect of the cement from the first
explosive unit
60 being faced down,. and from the second explosive unit 60 being forced up,
may result in
an adequate harrier ''CB", as shown in fig, 21), that conforms to industry
and/or regulatory
standards. An example of a shaped charge tool 10 comprising a top sub 12: and
haying two
explosive units 60 positioned, e.g:, 10,16 centimeters (.40 inches), apart
from each other is
shown in Fig, 2g.
[0099] Furthermore, three explosive units 60 may be detonated as follows. To
begirt with,
first and second explosive units 60 may be detonated 20,3 centimeters (8
inches) apart from
each other to create two spaced apart protrusions "P;" as shown in Fig. 2E.
The two
detonations form two barriers "8" shown in FiOr, 2E, with the first explosive
unit 60 forcing
the cement ''C" downward and the second explosive unit 60 fOrring cement "C"
upward.
third explosive unit 60 is then detonated between the first and second
explosive hints 60.
Detonation of the third explosive unit 60 further compresses the cement "C!'
that was forced
downward by the first explosive unit 60 and the cement "C" that was forced
upward by the
second explosive unit 60, to form two adequate barriers 'CB" as Shown in Fig.
2K
Alternatively, detonation of the third explosive unit 60 may result on one
battier above or
below the third explosive unit 60 depending on the cement competence in the
respective
zones. Either scenariO tone or two barriers) may further restrict/seal off
micro annulus leaks,
or cure the other cement defects discussed herein, to conform with industry
and/or regulatory
standards An example of a shaped charge tool 10 comprising a top sub 12 and
having three
explosive units 60 positioned, 04., 10.16 centimeters (40 inch*, apart from
each other is
shown in Fig, 21i,
23
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00] FIGS. 2G and 214 illustrate an embodiment in which =a detonation cord 61
for
initiating the tool is run through the length of the tool 10. Another way to
configure the
detonation cord 61 is to install separate Sections of detonation cords 61
between boosters 61a,
as shown in FM. 21_ Each booster 61a eau be filled with explosive material
61b, such as=
184X, That is, a first booster 61a, provided with a first explosive unit 60,
may be associated
with a first section of detonation cord 61, which first section of detonation
cord 61connects to
a second booster 61a located further down the tool 10 and provided with a
second explosive
unit 60. A second section of detonation cord 61 is provided between the second
booster 61a
and a third booster 61a, as shown in FIG. 21 If further explosive units 60 are
provided, the
sequence of a section of detonation cord 61 between consecutive boosters 61a
may be
continued.
[0101] The contingencies discussed with respect to Figs_ 2C through 2F may
address the
situation in which, even when cement bond logs suggest a cement column is
competent in a
particular zone, there may still be a variation in the cement volume and
density in that zone
requirement is more than one expansion charge.
[0102] In the methods discussed above, expansion of the inner tubular Ti
causes the sealant
displaced by the expansion to compress, reducing the number of micro pores in
the cement or
the number of other cement defects discussed herein. The expansion may occur
after the
sealant is pumped into the annulus "A". Alternatively, the cement c:ir other
sealant may be
provided in the annulus "A" on the portion of the wall of the inner tubular
TI, after the
portion of the wall is expanded. The methods may include selectively expanding
the inner
tubular Ti at a second location spaced from the first location to create a
pocket between the
first and second locations. The sealant may be provided in the annulus "A"
before the pocket
is formed. In an alternative embodiment, expansion at the first location may
occur before the
sealant i .r 1ded, and expansion at the second location may occur after the
sealant is
provided.
[0103] FIGS. 23 to 2L illustrate methods of selectively expanding at least a
=portion of the
wall of a tubular surround by formation (earth). FIG. 2J shows that the tool
10 is positioned
within the tubular Ti that is cemented into a formation that includes shale
strata and
sandstone strata. The cement "C" abuts the outer surface of the tubular TIon
one side, and
abuts the strata on the opposite side, as shown in FIG. 2J. Shale is one of
the more non-
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pprineubte earthen materials, and may be referred rO.as. a cap rock
fOrniatioti To the contrary,
Sandstone is known. to he permeable. Accordingly, When the tool =i 0 iS used
to in a
tubular/earth application to consolidate cement adjacent a formation, such: as
shown in FIG.
11, it is preferable to expand the wall of the tubular Ti that is adjacent the
cap rock formation
(e.g., Shale strata)= because the non-permeable cap rock fbrmation seals off
the annulus flow,
as shown in fia 2K. On the other hand, if the tool 10 was used to expand the
wall of the
tubular T1 that was adjacent the sandstone strata, as shown in FIG. 2L, even
if the cement
"C" is consolidated to seal against annulus flow through the consolidated
cement "C",
annulus flow can bypass the consolidated Cement "C" and migrate or flow
through the
permeable Sandstone strata (See FIG. 2L), defeating the objective of expanding
a wail of the
tubular T
[0104] FIGS, 2M and 2N illustrate a method of selectively expanding the walls
of two
concentric tubulars TI and 12 according to an embodiment. FIG. 2M shows an
inner tubular
Ti surrounded by an outer tubular T2, and an annulus between the inner tubular
TI and the
outer tubular T2 that includes a seal*, such as cement "C". A third tubular
T1, or ft-yrgoopn,
surrounds the outer tubular 12. The annulus between the outer tubular T2 and
the third
tubular 13 Of formation also includes a sealantõ such as cement `4C2". In the
embodiment,
annulus flow 'V may be present through in the cement "C" and ".C.2" in both
annuli. A tool
10, such as discussed herein, May be positioned within the inner tubular TI
(see FIG. 2N) to
selectively expand the. walls of both tubulan TI and T2 with a single
actuation of the tool l().
That is, detonation Of the explosive material in the tool 10 creates a force
that travels radially
outward to impact the inner tubular Ti and expand at least a portion of the
wall of the inner
tubular T1 radially outward without perforating or cutting through the portion
of the wall, to
form a protrusion '1?" of the inner tubular TI as shown in FIG. 23+:1, The
tool 10 may contain
an amount of explosive material based at least in part on a hydrostatic
pressure bearing on
one or more of the inner tubular Ti. the outer tubular 717, and the tool 10
itself. The
protrusion "P" extends into the annulus between the inner tubular TI and the
outer tubular 12
to compress the cement "C" to reduce the porosity of the cement "C" by
reducing the number
of pores, channels, or other cement imperfections allowing annulus leaks. The
compressed
cement is shown in FIG, 2N with the label "CC". Additionally, the radially
traveling force Of
the detonated explosive material, and/pr expat4ion of the protrusion 'I)",
iinpacts the outer
tubular 12 and expands at least a portion of the wall of the outer tubular 12
radially outward
without perforating or cutting through the portion of the wall, to tbrm a
protrusioil "P2' of
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the outer tubular T.2õ as shown in FIG. 2N, The protrusion
extends int.e the annulus
between the outer tubular T2 and the third tubular 13, or formation, to
compresses the cement
"CC2" in that annulus. The compression reduces the porosity of the Cement "Ccr
by
reducing the number of pores, ehannels, or other cement imperfections allowing
annulus
lea.lta, Thus, compressed cement "CC", "cc2" is consolidated M both annuli
with one
detonation of the explosive material contained in the tool 10. In the
embodiment of ElQ.
a single charge is used to form the protrusions "P", "Pr. However, multiple
charges, serially
oriented in the tool 10, could also be used to form multiple sets of the
concentric protrusions
.."13"õ "P2" along the axis of the welibore..
[0105] The reduced munber of poreS, channelS, Or other =cement imperfections
allowing
annulus leaks in the compressed cement "CC', "cc2" reduces the risk of seepage
into the
cement and helps seal against annulus flow through the consolidated cement.
Further, the
protrusions "P", "P2" may create a ledge or barrier that helps seal that
partion of the wellbore
from seepage of outside materials. The size and shape of the protrusions "P",
'P2" May vary
depending on several factors, including-, but not limited ta, the Size ..(04.,
thickness), strength
and material of the inner and outer tubulars TI. TZ the type and amount of the
explosive
material, the hydrostatic pressure bearing on the inner and otter tubulara Ti.
T2õ the desired
size of the protrusions "P", "P2", and the nature of the wellbore operation,
[01061 A variation of the tool 10 is illustrated in FK37,. 4, In this
embodiment, the axial
aperture 80 in the thrust disc 46 is tapered with a conically convergent
diameter from the disc
face proximate of the detonator 31 to the central aperture 62: The thrust disc
aperture $0 may
have a taper angle of about 10 degrees between an approximately 0õ2
centimeters (0.08
inches) inner diameter to an approximately 0.32 centimeters (0,13 inches)
diameter outer
diameter. the taper angle, also characterized as the included angle, is the
angle measured
between diametrically opposite conical surfaces in a plane that includes the
conical axis 13.
[01071 Original initiation of the FIG, 4 charge 60 occurs a the outer plane of
the tapered
aperture 80 haying a proximity to a detonator 31 that enables/enhances
initiation of the
charge 60 and the concentration of the resulting explosive force. The
initiation shod. wave
:propagates inwardly along the tapered aperture 80 toward the explosive
junction plane 64. As
the shock wave progresses axially along the. aperture 80, the concentration of
Onnk, wave
energy intensifies due to the progressively increased confinement and
concentration of the
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explosive :energy. Consequently, the detonator shock wave strikes the charge
units 60 at the
inner juncture plane 64 with an amplified impact. Comparatively* the same
explosive charge
units 00, as suggested for FIG, 1 comprising, for example, approximately 38.8
grams (1.4
ounces) of 1-1MX compressed under a loading pressure of about 20.7 Mpa (3,000
psi) and
when placed in the FIG. 4 embodiment, may require only a relatively small
detonator 3.1 of
HMX far detonation:. Significantly, the. conically tapered aperture 80 of FIG.
4 appears th
fdcus the detonator energy to the central aperture 62,, thereby igniting a
given charge with
much less source energy. in FIG& 1 and 4, the detonator 31 emits a detonation
wave of
energy that is reflected (bounce-back of the shock wave) off the flat internal
end-face :33 of
the integral end wall 32 of the housing 20 thereby amplifying a focused
concentration of
detonation energy in the central aperture 62 Because the tapered aperture $0
in the FIG. 4
embodiment reduces the volume available for the detonation wwvc, the
concentration. of
detonation energy becomes amplified relative to the FIG. 1 embodiment that
does not include
the tapered aperture 80_
[019$1 The yariation of the it)04 10 shown in fIG 5 !.e0:0,5 upon in open,
4tbstantially
cylindrical aperture 47 in the upper thrust disc 46 as Shown the
FIG. I embodiment.
HoweVer, either no Vernet is provided in the end plate boss 72 of FIG. 5 Or
the aperture 49
in the lower end plate 48 is filled with a dense, metallic. plug 76, as shown
in FIG. 5. The plug
76 may be inserted in the aperture 49 upon final assembly or pressed into
place beforehand.
As in the case of the Fici. 4 embodiment, the FIG% 5 tool 10 comprising, for
example,
approximately 38,8 grams (1.4 ounces) of FIMX compressed under a loading
pressure of
about 20.7 Mpa (3,000 psi), also may require only a relatively small detonator
31 of HIVIX for
detonation. The detonation wave emitted by the detonator 31 is reflected back
upon itself in.
the central aperture 62 by the plug 76, thereby amplifying a focused
concentration of
detonation energy in the central aperture 62.
[01091 The FIG-. 6 variation of the tool 10 combines the energy concentrating
features of
FIG. 2 and FIG 5, and adds a relatively striall, explosive initiation pellet
66 in the central
aperture 62. In this case, the detonation wave of energy emitted from the
detonator 31 is
reflected off of explosive initiation pellet 66. The reflection from the off
of explosive
initiation pellet 66 is closer to the juncture plane 64, which results in a
greatcT concentration
of energy (enhanced explosive force). The explosive initiation pellet 06
concept can be
applied to the FIG. 1 embodiment, also.
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[0110] Transporting and storing the explosive units may be hazardous. There
are thus safety
guidelines and standards governing the transportation and storage of such. One
of the ways to
mitigate the hazard associated with transporting and storing the explosive
units is to divide
the tants into Waller component pieOes. The smaller component pieces May not
pose the
same explosive riSlc during transportation and storage as a full-size unit may
have. EaCh of
the explosive units 60 discussed herein may thus be provided as a set of units
that can be
transported unassembled, where their physical proximity to each other in the
shipping box
would prevent mass (sympathetic) detonation if one explosive component was
detonated, or
11., in a fire, .1vould burn and .nOt detonate. The set is configured to he
easily Skin:bled at the
job site,
[0111] Fig, 10 shows an exemplaty embodirrient of a set 100 of explosive
units.
Embodiments of the explosiVe units disCussed herein may be configured as the
set 100
discussed below. The set 100 comprises a first explosive unit 102 and a second
explosive unit
104, Each of he first explosive. unit 'Or and the Second explosive unit 104
comprises the
explosive Material discitsSed herein. Each explosive unit 102,, :104 may be
frusto-conically
shaped, hi this configuration, the first explosive unit 102 includes 0 smaller
area first surface
106 and a greater area second surface 110 opposite to the smaller area first
surface 106.
Similarly, the second explosive unit 104 includes a smaller area first surface
108 and a
greaor area second surface 112 opposite to the smaller area first surface 108.
Each of the first
exploSiye unit 102 and the second explosive unit 104 may be s).nunetric about
a longitudinal
axis 114 extending through the units, as shown in the perspective view of FIG.
11. Each of
the first explosive unit 102 and the second explosive unit 104 comprises a
center portion 120
having an aperture 122 that extends through the center portion 120 along- the
longitudinal axis
114,
[01121 in the illustrated embodiment, the smaller area firSt snrfue 106 Of the
first explosive
unit 1.02 includes a recess 116, and the smaller area first surface 108 of the
second :explosive
unit 104 comprises a protrusion 118. The first explosive unit 102 and the
second explosive
unit 104 are configured to he connected together with the smaller atea first
surface 106 of the
first explosive unit 102 Wog the second explosive unit 104, and the smaller
area first
surface 108 of the seeptict explosive unit 104 facing the smaller area first
surface 106 of the
first explosive unit 102. The protrusion 118 of the second explosive unit 104
fits into the
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recess 116 of the first ep1oe unit 102 to j(.8in the first explosive unit 102
and the second
explosive Unit i 04 together, The first kplosiVe unit 102 and the second
exploSive unit 104
can thus be easily connected together without using tools or other materials,
[01131 In the ernbodiment, the protrusion 118 and the recess 116 have a
circular shape in
planform, as shown in Figs. 11 and 1/n other embodiments, the promision 118
and the
recess 116 may !lave a different shape. For instance, Fig, 13 shows that the
shape of the
protrusion 118 is square. The corresponding recess (not shown) on the other
explosive unit in
this embodiment is also square to fitably accommodate the protrusion 118.
Alternative shapes
for the protrusion 118 and the recess 116 may be triangular, rectangular,
pentagonal,
hexagonal, oetagonal or other polygonal shape having more than two sides.
[01141 Referring back to FIG. 10, the set 100 of explosive units can include a
first explosive
sub unit 202 and a second explosive sub unit 204. The first explosive sub unit
202 is
configured to be connected to the first explosive unit 102, and the second
explosive sub unit
204 is configure4 to be connetted to the second explosive wiit 104, as
discussed below.
Similar to the first and second explosive units 102, 104 diseussed above, each
of the first
&plosive sub unit 202 and the second explosive sub unit 204 can be frusto-
conical so that the
sub units define smaller area first surfaces 206, 208 and greater area second
surfaces 210, 212
opposite to the smaller area first surfaces 206, 208, shown in FIG. 10.
[01151 In the embodiment shown in FIG. 10, the larger area second surface 110
of the fifSt
explosive unit 102 includes a first projection 218, and the smaller area first
surface 206 of the
first explosive sub unit 202 includes a first cavity or recessed area 216. The
first projection
218 fits into the first cavity or recessed area 216 to join the first
explosive twit 102 and the
first explosive sub unit 202 together. Of course, instead of having the first
pro iection 218 on
the first explosive unit 102 and the first cavity ot recessed area 216 on the
first explosive sub
unit 202, the first projection 218 may be provided on the smaller area first
surface 206 of the
first explosive sub unit 202 and the first cavity 216 may be provided on the
larger area second
surface 110 of the first explosive unit 102,
[01161 Ftp, 1.0 4140 shows: that the larger area second surface 112 of the
second exploSive
unit 104 comprises a first cavity or rocgs&i: area 220, and the smaller area
first surface 20$ of
the second explosive sub unit 204 comprises a first projection 222. The first
projection 222
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fits into the Opt cavity or recessed area 220 to jOin the second explative
unit 102 and the
second explotiVe tub unit 204 together: Of cotitte, instead of having the
first projection 222
on the second explosive sub unit 204 and the first cavity 220 on the second
explosive unit
104, the first projection .222 may be provided on the larger area second
surface 112 of the
seeOpd explosive unit 104 and the first oviti,,-22o may be provided on the
smaller area first
surface 208 of the. second explosive sub unit 204. The first and second
explosive sub units
202, 204 may also include the aperture 122 extending along the longitudinal
axis 114.
[0117] FIGS. 10 and 11 show that the first explosive unit 102 includes a side
surface 103
connecting the stnaller area first surface 196 and the greater area second
surface 110.
Similarly, the second explosive unit 104 includes a side Stirface 105
connecting the Sinaller
area first surface 108 and the greater area second surface 112. EaCh side
surface 193, 105
may consist of only the explosive material, so that the explosive material is
exposed at the
side surfaces 103, 105, In other words, the liner that is conventionally
applied to the
explosive nnits is absent from the first and second explosive units 102, 104.
The side surfaces
107, 109 of the first and second explosive nib units 292, 204, respectively.,
can. consist of
only tho explosive material, so that the explosive material is: exposed at the
side surfaces 107,
109, and the liner is absent from the first and second explosive sub units
202, 204.
[01181 Figs, 14-17 illustrate another embodiment of an explosive unit 300 that
may be
included M a sot of several similar units 300. The explosive twit 300 may be
positioned in =a
tool 10 at a lOcatiOn and orientation that is opposite a similar explosive
unit 300, in the same
manner as the explosive material units 60 in Figs. 1 and 4-6 discussed herein,
Fig, 14 is a
plan view of the explosive unit 300, Fig. 15 is =a plan view of one segment
302 of the
explosive unit 300, and Fig, 16 is a side view thereof. Fig, 17 is .a
cross,sectional side view of
Fig. 13. In the embodiment, the explosive unit 300 is in the shape of a
frustoconical disc that
is formed of three equally-sized segments 391, 302, and 303. The explosive
unit 300 may
include a central opening 304, as .shown in Fig. 14, for accOnimodating the
Shaft of an
explosive booster (hot shown). The illustrated embodiment Shows that the
explosive unit 300
is ibrmed of three segments 301, 302, and 303 each accounting for one third
(i.e, 120
degrees) of the entire explosive unit 300 (i.e, 360 degrees). However, the
explosive unit 300
is not limited to this embodiment, and may include two senents or four or more
segments
depending nature of the explosive: material forming segments. FOr instance, a
more highly
explosive material may require a greater number of (smaller) segments in order
to comply
CA 03203289 2023-05-26
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with incinstqt regulations for safely transporting explosive material, For
instance, the
explosive unit 300 may be formed of four segrnentS, each aecounting :for One
quartet (i.e., 90
degrees) of the entire explosive unit 300 (ie., 360 degrees); or may be formed
of six
segments, each accounting for one sixth (Le, 60 degrees) of the entire
explosive unit 300
3.60 degrees). According to one entbodimetn, each segment 'should include nO
mine than
38$ grains (1.4 ounces) of explosive material.
[0119] In one embodiment, the explosive unit 300 may have a diameter of about
8.38
centimeters (3.3 inches). Figs, 15 and 16 Show that the Segment 302 has a top
surface 305 and
a bottom portion 306 having a side wall 307. The top surface 305 may be
slanted an angle Of
17 degre0 from the central opening 304 to the Side wall 307 in an embodiment.
According, to
one ernbodiment, the overall height of the segment 307 may be about 1.905
centimeters (0.75
inches), With the Side wall 307 being about 0,508 Centimeters (0,2 inches) of
the overall
height. The overall length of the segment 302 may be about 7.24 centimeters
(2,5 inches) in
the embodiment. Fig. 17 Shows that the inner bottom surface 308 of the segment
302 may be
inclined: at 4i angle of 12 degreo,, 4ceording to one embodiment The width of
the bottom
portion 306 may be about 1:37 centimeters: (0.54 inches) according to an
embodiment with
respect to Fig. 17. The side wall 309 of the Central opening 304 may have a
height of about
0,356 centimeters (0.14 inches) in an embodiment, and the uppermost part =310
of the
segment 302 may have a width of the about 0,381 centimeters (0.15 inches), The
above
dimensions are not limiting, as the segment size and number may be different
in other
emboditnerits. A different segment sizee andior number may have different
dimensions. The
explosive units 300 may be provided as a set of units divided into segments,
so that the
explosive units :300 can be transported as unassembled segments 301, 302, 303,
as discussed
above.
[01201 The set of segments is configured to be easily assembled at the job
site. Thus, a
method of selectively expanding at least 4 portion of a wall of a tubular at a
well site via 4
shaped charge tool 10 may include first receiving an unassembled set of
explosive units 300
at the well site, wherein each explosive unit 300 comprising explosive
material, is divided
multiple segments 301, 302, 30:3 that, when joined together, form an explosive
unit 300, The.
method includes assembling the 001 10 (see, e.gõ I)
comprising a shaped charge
assent* Comprising a housing 20 and two end plates 44, 48. The housing 20
comprises an
inner surface 51 racing tln interior of the housing 20. At the well site, the
segments 301, 302,
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303 of each explosive unit 300 are together to form the asserohled explosive
unit 300., The
expIOSive units 300 are then positioned between the two end plates 46, 48, fa
instance each
explosive unit 300 is adjacent one of the end plates 46, 48, so that an
exterior surface of the
explosive material of explosive units 300 faces the inner surface 51 of the
housing 20. In an
enibodiment, the explosive material is expos0 to the inner surface 51 of the
housing 20.
Next, a detonator 31 is positioned adjacent to one of the two cod plates 46,
48, and the shaped
charge tool 10 is positioned within the tubular. The detonator 31 is then
actuated to ignite the
explosive material causing a shock wave that travels radially outward to
impact the tubular at
a first location and expand at least a portion of the wall of the tubular
radially outward
without perfOrating or cutting through the portion of the wall, to form a
protrusion of the
tubular at the portion of the wall. The prottusion extends into an annulus
between an outer
surface of the wall of the tubular and an inner surface of :a wall of another
tubular or a
formation.
[01121] FIGS, IS - 22 Show embodiments of a centralizer assembly that. may be
attached to
the housing 2Ø The centtor40 assembly centrally confines the toijl 10 within
the inner
tubular IL in the embodiment shown in Fig. 1:8,= plan-from view of the
centralizer assembly
is shown in relation to the longitudinal axis 13. The tool 10 is centralized
by a pair Of
substantially circular centralizing discs 316. Each of the centralizing discs
3.1.6 are secured to
the housing 20 by individual anchor pin fasteners 318, such as screws or.
rivets. In the FIG. 18
embodiment, the discs 316 are mounted along a diameter line 320 across the
housing 7Ø, Ny4h
the most distant points on the disc perimeters separated by a dimension that
is preferably at
least corresponding to the inside diameter of the inner tubular Ti. in many
eases, however, it
will be desirable to have a disc perimeter separation slightly greater than
the internal diameter
of the inner tubular IL
[01221 In another embodiment shown by FIG, 19. each of the three discs 316
are. secured by
Separate pin fasteners 318 to the housing 20 at approximately 120 degree
arcuate spacing
about the longitudinal axis 13. This' configuration is representative Of
applications fbt,
multiplicity of centering discs on the housing 20. Depending on the relative
sizes of the tool
and the inner tubular Ti, there may be three or more such discs distributed at
substantially
uniform arcs about the tool circumference,
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1.01:31 FIG, 20 shows, in planform, :another embodiment of the centralizers
that includes
Spring steel centralizing wires 330 of small gage diameter: .A plurality of
these wires is
arranged radially from an end boss 332. The wires 330 can be formed of high-
carbon steel,
stainless steel, or any metallic or metallit composite matedal with sufficient
flexibility and
tensile strength. While the embodiment includes a total of eight centralizing
wires 330, it
Should be appreciated that the plurality may be made up of any number of
centraliling wires
330, or in some cases, as few as two. The use of centralizing wires 330 rather
than blades or
other machined pieces, allows for the advantageous maximization of space in
the flowbore
around the centralizing system, compared to previous spider-type centralizers,
by minimizing
the crosS-seetion compared to systems featuring flat blades or other planar
configurations. The wires 330 are oriented petpendicular to the longitudinal
ax:is 13 and
engaged with the sides of the inner tubular, which is 'positioned within an
outer tubular T2;
The wires 330 may be sized with a length to exert a compressive force to the
tool 10, and flex
in the same fashion as the cross-section of discs 316 during insertion and
withdrawal.
[0124) Another embodiment of the centralizer assembly is Shown in El(1, 21,
This
configuratiOn comprises a plurality of Omar blades 345a, 345b to centralize
the 001 10, The
blades 345a, 345b ate positioned cm the bottom surface of the tool 10 via a
plurality of
fasteners 342. The blades: 345a, 345b thus flex against the sides of the inner
tubular T I to
exert a centralizing force in substantially the same fashion as the disc
embodiments discussed
above. F10õ 18 illustrates an embodiment of a single blade 345. The blade 345
comprises a.
plurality of attachment points 344a, 344b, through which fasteners 342 seCiite
the blade 345
in position, Each fastener 342 can extend through a respective attachment
point to secure the
blade 345 into position. While the embodiment in FIG, 21 is depicted with two
blades 345a,
345b, and each blade 345 coraptises two attachment points, for a total of four
fasteners 342
and four attachment points (344a, 344b are pictured in HO. 22), it should be
appreciated that
the centralizer assembly may cOmprise any number of fastenets and attachment
points.
[01251 The multiple attachment points 344a, 344b on each had .345, being
spaced laterally
from cattl.. other, prevent the unintentional rotation of individual blades
345, even in the event
that the fasteners 342 arc slighdy loose from the attachment points 344a,
344b, The fasteners
342 on be. of .aoy tyo of fastener usable f;Or securing the blades into
position, including
screws. The blades 345 cat be spaced laterally and oriented perpendicular to
each other, ft)r
centralizing the tool 1.0 and preventing unintentional rotation of the one or
more blades 345.
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[0126] While the disclosure abaft discusses embodiments in which there is no
liner on the
exterior surface 50 of the explosive units 60 (ix, the exterior surface 50 of
the explosive
units 60 is exposed to the inner surface 51 of the housing 20), alternative
embodiments of the
present disclosure may inchule a litlet 50a on the exterior surface of the
explosive units 60, as
oiowp in na 24, and may be able to achieve similar results as the liner-less
explosive units
60 according to the following criteria. Conventionally9 liners for explosive
units were formed
of material with relatively high density and ductility so that, when collapsed
by a detonation
wave of the ignited explosive units, the liners form a jet that is strong
enough to penetrate the
pipe or tubular in a cutting or perforating operation. Conventional materials
for such liners
intluded topper, nickel, zinc, zinc alloy, irOrt, 0, bismuth, and tungsten.
[0127] On the other hand, a lina formed of a relatively tow density and
brittle material
would not jet as well as the conventional materials discussed above The
present inventor has
determined that a formed of a material that is less dense and ductile than
copper, nickel, zinc,
4ine alloy, iron, tin, bismuth, and tungsten, individually or in conibinatjon,
(i.e., formed of a
material that is brittle and has law density), may be effective in expanding,
without
puncturing, the wall of the tubular TI to form the protrusion "P' discussed
herein. in this
regard, an enibodiment of the liner 50a may have a density of 6 gice or less,
and may be less
ductal than copper, nickel, zinc, :zinc alloy, iron, tin, bismuth, and
tungsten, individually or in
combination. In an embodiment the liner 506. may be :formed of glass material.
In another
emboditnent, the liner 50a may be formed of a plastic material.
[0.128] Another way to reduce the potency of the liner jet, so that the jet
may expand, without
puncturing, the wall of the tubular TI to form the protrusion "P" discussed
herein, is to
perforate the liner 50a. In addition, or in the alternative, the liner 50a may
be formed so that a
density, w,all thickness, and/or :composition of the liner 50a is asymmetric
around at least one
of the explosive units 60. Itt addition, or in the alternative, the explosive
units 60 may be
formed so that a density, wan thickness, and/or composition of the explosive
units 60 is
asymmetric around at least one of the explosive units 60õ Further, the liner
50a of at least one
of the explosive units 60 may be geometrically asymmetric. Asymmetric
explosive units 60
may reduce the potency of explosive units 60 so that detonation of the
explosive nnits 60 may
expand, without puncturing, the w411 of the tubular TI to for, the protrusion
discussed
herein, Similarly, asymmetric liners may reduce the potency of the jet formed
by the liners,
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so that the jet may expand, without puncturing, the wall of the tubular T) to
form the
protrusion "P"diScuSSed herein.
[0129] FIG. 25 illustrates another embodiment of a tool 10 for selectively
expanding at least
a portion Of a Wall of a tubular. The tOC4 10 in this embodiment coMpriseS a
liner 50e on the
outer surface of the explosive units 60. The liner 50c :may be a liner fermed
of the
conventional materials discussed above (e.g., copper, nickel, zinc, zinc
alloy, iron, tin,
bismuth, and tungsten). The tool 10 further comprises an extraneous object 55
located
between the inner surface of the housing 20 and the liner 50c. The extraneous
object 55 fouls
the jet tbrined by the liner 500 so that the jet expands. Without puncturing,
a: portiOn of the
wall of the tubular T1 to form a protrusion 1=1" extending outward into an
annulus; adjacent
the wall of the tubular TI, as discussed herein. The extraneous object 55 may
he one of a
foam object, a rubber object, a wood object, and a liquid object, among other
thing&
[01301 NG& 26A-26D illustrate a method of reducing a leak 505, such as a micro
annulus
leak as discussed herein, in an annulus 50; adjacent a tubular 501 in a
well:bat* 509. "Me
method may also be implemented, for example, in a plug-and-abandonment
operation. FIG.
26A Shows an example of a wellbote 500 that includes an annulus 502 disposed
between an
inner tubular 501 and an outer tubular, or formation, 504. The tubular 501 may
be the same or
akin to the tubular(s) discussed herein. The annulus 502 may contain a sealant
503, Such as
cement, A leak 505 may exist in the annulus 502: The leak 505 may be an oil
leak, a gas leak,
era combination thereof: The method may begin with setting a plug 506 41 a
location within
the tubular 501 as shown in FIG. 26B to prevent fluidõ gases, and/or other
wellbore materials
from traveling up the tubular 501 past the plug 506. The plug 506 may be a
cast iron bridge
plug, a cement plug, or any plug Which isolates the lower portion of the well
from the upper
portion of the welt The plug 506 may also be used to seal the tubular 501
andlor provide a
stop for a sealant, such as :cement, that may be pumped into the annulus 502
from the tubular
501 in the folloWing manner. One or More puncher charges (not shown) 'frilly
be inserted into
the tubular 501 and actuated to punch holes 507 in the wall of the tubular 501
at a location
uphole of the plug 506, as Shown in F1Q, 26C. The puncher charges may be any
commercially available shaped charges that when detonated, form a jet of
limited length to
"punch" a hole in the target pipe without damaging any member beyond the
target pipe, The
holes 507 can serve as passages for a sealant; such as cement, that can be
subsequently
pumped, or otherwise providedõ into the tubular 501 and squeezed through the
holes 507 int)
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the annulus 502, As Shown in Fig. 260, the sealant (e ;:gõ. content) is
squeezed through the
holes 507 and into the annuins 502 to densify the sealant (sec densified
sealant 508) that is
already present in the annulus 502, or otherwise to fill the annulus 502, for
sealing or
reducing the leak 505. By sOme estimates, the method of reducing the leak 505
in the annulus
502, as discnssed with respect to FIcil$: 26A to 261).. may be only 35%
:successful,
[01311 A more successful method of reducing a leak 505 in the annulus 502,
adjacent a
tubular 501 in a wellbore 500, is shown in FIGS. 27A to 27E. FIG. 27A
illustrates a scenario,
as discussed above, in which a leak 505 exists in the annulus 502 adjacent a
tubular 501 in a
wellbore 500. As before, a plug 506 may be set at a location within the
tubular 501, as shown
FIG. 27B. The plug 506 may be the sante its the plug 506 discussed above, Next
an
expansion tool 509, containing an amount of explosive material, is insetted
into the thbular
501 uphole of the plug 506 as shown in FIG. 27C. The expansion tool 509 may be
any one of
the expansion tools and their variations as discussed herein, The explosive
material may be
any of the explosive materials discussed herein or other HMX., RDX or ENS
material. Other
characteristies of the tubular andlor the welibore may also be determined and*
accounte.d
for, as discussed above, as necessary or as desired to determine the amount of
explosive
Material in the expansion tool 509. The amount of explosive material in the
expansion tool
509 may be based at least in part on a hydrostatic pressute bearing on the
tubular 501 in the
Vvellbore 500, as discussed herein. The amount of explosive material produces
an explosive
force sufficient to expand, without puncturing, the wall of the tubular 501.
The expansion
tool 509 may then be actuated to expand the wall of the tubular 501 radially
outward, Without
perforating or cutting through the wall of the tubular 501 to form one or more
protrusions
510 as shown in HQ, 27C, Each protrusion 510 extends into the annulus 502
adjacent an
outer surface of the wall of the tubular 501, in the manner(s) discussed
herein. The
protrusions 510 may seal oft or inay help seal off; the annulus 502 by
protruding toward or
against the outer pipe 504 (or formation) surrounding the annulus 502. For
instance., FIG,
27C Shows that the protrusions 510 may densify the sealant (see densified
sealant 508)
already present in the annulus 502, or otherwise fill the annulus 502, to seal
or reduce the
leak 505. The protrusions 510 may seal off, or may help seal off, the annulus
502 against
leaks in the sealant 503 by compressing any voids in the sealant 503 and/or
collapsing open
channels in a cemented annulus 502. In :some cases, the protrusions 510
extending into the
annulus may be enough to provide an acceptable seat against the leak 505
Moving uphole
beyond the protrusions 510, and no further remedial action may be required. By
some
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estimates, the manner (yf reducing the leak 505 in. the annulus 502 as
discussed with respect to
FIGS. 27A to 27C May be at least 70% suceesSful, To increase the success rate,
if needed,
additional steps to reduce the leak 505 in the annulus 502 are shown in FIGS,
27D and 27E,
[01321 In particular, one or more puncher charges (not shown) may be
subsequently inserted
into the tubular 501 and actuated to punch holes 507 in the wan of the tubular
501 as shown
in FIG. 27Ø The puncher charges may be the same as those discussed above, As
discussed
above; the boles 507 serve as passages for a sealant, such as cement, to
subsequently be
pumped, or otherwise provided, into the tubular $01 and squeezed through the
boles 507 into
the annulus 502, at least down to the upper protrusion 510. As shown in FIG.
:27E, the sealant
colon) can be Sqiieted through the holes 507 into the annuhiS 502 to densify
the
sealant (see densified sealant 508) already present in the annulus 502, or
otherwise to till the
annulus 502, for sealing or reducing the leak 505, at least down to the upper
protrusion 510.
In some cases, however, the cement squeezed through the holes 507 may travel
down beyond
the upper protrusion 510 if any voids or channels in the densifted sealant 508
are large
enough to permit such flow, In addition, the protrusions 510 may fotm a
restriction or a ledge
below where the cement 507 will be introduced into the annulus 502. If the
sealant is viscous
enough, the protrusion 510 may provide the annulus seal by itseif By Some
estimates, the
method of reducing the leak 505 in the annulus 502 as discussed with respect
to HOS. 27D
and 27E niav be at kaSt 90% successful,
[0113] In the embodiments discussed above expansion tools including one or
more
expansion charges have been discussed. The expansion charges may be shaped
charges as
discussed abovev liowever, a dual end firing tool or single end firing tool
may also be used to
expand, without puncturing, the wall of the tubular to form a protrusion
extending outward
into the annulus adjacent the wall of the tubular as discussed herein. Dual
end fired and single
end fired cylindrical CxplosiVe Column tools (e.g., modified prossot balanced
or pressure
bearing severing tools) produce .a focused energetic 'reaction, but with unich
less: focus than
from shaped charge expanders. In dual end fired explosive column was, the
focus is
achieved via the dual end firing of the explosive column, in which the two
explosive wave
fronts collide in a middle part of the column, amplif*g the pressure radially.
In single end
fired explosive column tools, the focus is achieved 0.4 the firing of the
explosive column
from one end which generates QM wave front producing comparatively less
energy. The
single wave front May form a protrusion in the wall of the tubular, without
perforating or
37
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cutting through the wall. The prO03410 formed by a single end fired exp104ive
Column ool
may be asymmetric as compared With a protrusion formed by a dual end fired
explOSive
column tool. The length of the selective expansion in both types of explosive
column tools is
a function of the length of the explosive column, and may generally be about
two times the
length of the explosive Column. With a relatively longer expansion length, for
example, 40.64
centimeters (16.0 inches) as compared to a 10.16 centimeter (4.0 inch)
expansion length with
a shaped charge explosive device, a much more gradual expansion is realized.
The more
gradual expansion allows a greater expansion of any tubular or pipe prior to
exceeding the
elastic strength of the tubular or pipe, and failure of the tubular or pipe
(1,e,, the tubular or
pipe being breeched),.
[0:1.341 An embodiment of an expansion tool 600 for selectively expanding at
least a portion
of a wall of a tubular is shown in FIGS. 28.,30, The expansito tool 600, as
shown in this
embodiment, is a dual end firing explosive column tool, and can be used for
applications
involving relatively large and thicker tubulars, such as pipes having a 6,4
centimeter (23
inch) %kid thickness, an inner diameter of 77,9 centiinetets (9,0 inches) or
more and an outer
diameter of 35,6 centimeters (14.0 inches) or more. However, the dual end
firing explosive
column tool 600 is not limited ti) use With such larger tubularS, and ratty
effectively be used to
expand the wall of smaller diameter tubtdars and tubulars with thinner walls
than discussed.
above, or with larger diameter tubulars and tubuiars with dikter walls than
discussed above.
[013fl FIQ; 2$ Shows a cross..k..,(.1ional view of an embodiment of the dual
end firing
explosive column tool 600. In this embodiment, the dual end firing explosive
column tool
1500 is a modified pressure balanced tool. FIGS. 29 and :30 show details of
particular portionS
of the dual end firing explosive column tool 600. As shown, the dual end
firing explosive
column tool 600 can include a top sub 612 at a proximal end thereof. An
internal cavity 613
M the top sub 612 can be termed to receive a firing bead (not shown): A guide
tube 616 can
be sectued to the top sub 612 to project from an inside face 03$ of the top
sub 612 along an
axis Of the tool 600, The opposite distal end of guide tube 616 can suppOrt a
guide tube
terminal 618, which can be shaped as a disc. A threaded boss 619 can secure
the terminal 618
to the guide tube 616. One or MOM resilient spactra 642; such as silicon foam
washers, can be
positioned to encompass the guide tube 616 and beat against the upper face of
the terminal
618.
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101361 'the dual end firing explosive column WO 600 can be arranged to
serially align a
plurality of high OtplOsiVe pellets 640 along a central tube to fortn an
explosive column. The
pellets 640 may be pressed at forces to keep well fluid from migtating into
the pellets 640. In
addition, or in the alternative, the pellets 640 may be coated or sealed with
glyptal or lacquer,
or other tOmpound(s), to prevent well fluid from migrating into the pellets
640, The dual end
firing explOsive column tool 600, as shownõ is provided without an exterior
housing so that
the explosive pellets 640 can be exposed to an outside of the dual end firing
explosive
column tool 600, meaning that there is no housing of the dual end firing
explosive column
tool 600 covering the pellets 640, That is, when the dual end firing explosive
column tool 600
is inserted into a pipe or other tubular, the: explosive pellets 640 can be
exposed to an inner
stittliCe of the pipe or other tubular. AlternatiVely, a Sheet of thin
material, or ":Cab housing's
(opt shown) may be provided with the dual end firing explosive column tool 600
m cover the
pellets 640, for protecting the explosive material during running into the
well. The material of
the "scab housing" can be thin enough so that its effect on the explosive
impact of the pellets
640 on the surface of the pipe or other tubular is immaterial. Moreover+ the
exploSive force
co= vaporize or pulverize the 'scab housing" so that no debris from the: "KO
housing" is. left
in the wellbore. some embodiments, the ''.scab housing' may be formed of
Teflon, PEEK,
ceramic taaterialsõ Or highly heat treated thin metal above 40 Rockwell "C".
131-directional
detonation boosters 624, 626 are positioned and connected to detonation cords
630, 63:2 for
simultaneous detonation at opposite ends of the explosive column. Each of the
pellets 640
can comprise about 22,7 grams (001 ounces) to about 38,8 grams (1.37 ounces)
of high
order explosive, such as RUN, tiMX r FINS. The pellet density Can be from,
e.g.:, about 1.6
glom' (0,92 ortin) to about 1+65 g/cm3 (0.95 az103), to achieve a shock wave
velocity greater
than about 9,144 meters/sec (30,000 ft/sec), for example.
[0:1:37] A shod( wave of such magnitude can provide a pulse of pressure in the
order of 27.6
Gpa (4 x 1.0' psi). It is Me pressure pulse that expands the wall of the
tubular_ The pellets 640
can be compacted at a production facility into a cylindrical shape for
:serial, juxtaposed
loading at the jobsite, as A. column in the dual end firing explosive column
tool 600, The dual
end firing explosive column tool 600 can be configured to detonate the
explosive pellet
column at both ends simultaneously, in order to provide a shock front from one
end colliding
With the shot* front to the opposite end within the pellet eohunn at the
center of the column
length. On collision, the pressure IS multiplied, at the point of collision,
by about:four to five
times the normal pressure cited above. To achieVe this result., the
Simultaneous firing of the
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bktirectionai d0Q1latipp bOOSterS 6245 626 can, be timed precisely in order to
assure c011isiori
within the (*plosive column at the: center. In an alternative embodiment, the
expansion tool
600 may be a single end firing explosive column tool that includes a
detonation booster at
only one end of the explosive pellet column, $0 that the explosive column is
detonated from
only the one end adjacent the detonation booster, as discussed above, and so
the configuration
of the single end Ming explosive column tool is similar to that of the dual
end firing
explosive column tool discussed herein.
[0138] TOward the upper end of the guide tube 616, an adiustably positioned
partition disc
620 OM be wined by:a set sCrew 621. Between the parth ion disc .620 and the
inside face 638
of the top sub 612 can be a timing Spool 622, as Shcnvti. in FIG 28, A first
hi-directiOnal
booster 624 can be located inside of the guide tube bore 616 at the proximal
end thereof; One
end of the first hi-directional booster 624 may abut against a bulkhead formed
as an initiation
pellet 612a. The first hi-directional booster 624 can have enough explosive
material to ensure
the requisite energy to breach the bulkhead. The opposite end of the first hi-
directional
booster 624 can comprise pair of mild detonating cords 610 and 632, which can
be secured
within detonation proximity to a small quantity of explosive material 62,5
(See RP. 29).
Detonation proximity is that distance between a particular detonator and a
particular receptor
explosive within which ignition of the detonator will initiate a detonation of
the receptor
explosive. The detonation cords 630 and 632 can have the same length so as to
detonate
opposite ends of the explosive column of pellets 640 at the Same time. As
shown. in MS. 28
and 30, the first detonating cord 630 can continue along the guide tube 616
bore to be Secured
within a third hi-directional booster 626 that can be proximate of the
explosive material 627.
A first window aperture 634 in the wall of guide tube 616 can be cut opposite
of the third bi-
directional booster 626,, as shown. As shown in FIGS, 28 and 29, from the
first hi-directional
booster 624., the second detonating cord 632 can be threaded through a second
window
aperture 630 in the upper *A1l of guide tube 616 and around the helical
surface channels of
the timing spool 622. The timing spobl, which is outside the cylindrical
surface, can be
helically channeled to receive a winding lay of detonation cord with
insulating material
separations between adjacent wraps of the cord. The distal end of second
detonating cord 632
can terminate in a second hi-directional booster 628 that is set within a.
receptacle in the
partition disc 620. The position of the partition disc 620 can be adjustable
along the length of
the guide tube 616 to accommodate the anticipated number of explosive pellets
640 to be
loaded,
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[0i 39] To load the dual end firing &plosive 'column tool 600, the Ode tube
terminal 618
can be removed along with the resilient spacers 642 (See FIG. 30). The pellets
640 of
powdered, high explosive -material, such as RDX, MIX or FENS, can be pressed
into narrow
Wheel shapes. The pellets 649 may he coated/sealed, as disettssed above : A
central aperture
can be provided in each pellet 640 to receive the guide tube 616 theretbrough
Transportation
safety may limit the total weight of explosive in each pellet 640 to, for
example, less than
38:8 grams (600 grains) (1.4 ounces). When pressed to a density of about L6
gicm3 (0.92
0494 to about 1,65 gicm3 (0,95 min), the pellet diameter may determine the
pellet
thickness within a deterMinable limit range.
101401 The pellets 640 can be loaded serially in a column along the guide tube
616 length
with the first pellet 640, in juxtaposition against the lower face of
partition disc 620 and in
detonation proximity with the second bi-directional booster 628. The last
pellet 640 most
proximate of the terminus 618 is positioned adjacent to the first window
aperture 634. The
number of pellets 640 loaded into the dual end firing explosive column tool
600 can vary
along the length of the tool 600 in order to adjust the sire of the shock WM
that results froth
igniting the pellets 640. The length of the guide nibe 616, or of the evlosive
column fOrmed
by the pellets. may depend on the calculations or testing diScussed below.
Generally, the
expansion length of the wall of the tubular can be about two times the length
of the column of
explosive pellets 640. In testing performed by the inventor, a 19.1
centimeters (7.5 44)
column of pellets 640 resulted in an expansion length of the. Wall of a
tubular of 406
centimeters (16 incheS) (A, a ratio Of column length to expansion length of I
to 2.13). Any
space remaining between the face of the bottom-most pellet 640 and the guide
tube terminal
618 due m fabrication tolerance variations may be tilled, with resilient
spacers 642,
[0141] FIci.S. 31-33 i 1 ustra Le another embodiment of an expansiou tool
600'. The expansion
tool 600' in this embodiment iS a modified pressure bearing pellet tool, and
differs from the
modified pressure balanced pellet toOl of FIGS. 28-30 in that the modified
pressiue bearing
pellet tool 600' includes a housing-, 610 having an internal bore 611, in
which the guide tube
616 and explosive pellets 640 are provided. The internal bore 611 can be
seale.d at its lower
end by a bottom nose 614. The interior face of the bottom nose 614 can be
cushioned with a
resilient padding 615, Such as a silicon foam Washer, lin other tespectS, the
modified pressure.
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bearing pellet tool 60(Y is similar to the modified pressure balanced pellet
tool 600, and so
like components are similarly labeled in FIGS. 31-31
[01421 A method of selectively expanding at least a portion of the wall of a
pipe or other
tubular nsing, the expansion tool de4erthed herein: may he as follows The
expansion tool may
be either the modified pressure balanced tool 600 of FIGS. 28-30, ot the
modified pressure
bearing tool 600' of FIGS:, 31.,33., The tkpaiistotx tool.i assembled by
arranging
predetermined number of explosive pellets 640 on the guide tube 616, which can
be in a
serially-arranged column between the second and third bi-directional boosters
628, 626, so
that the explosive pellets 640 are exposed to an outside of the expansion
tool. The expansion
tool is then positioned within a. tubular TI that is to be expanded, as shown
in PIO, 34A,
[01431 As shown in Fla 34A9 the tubular Ti May be an inner tubular that is
located within
an outer tubular 12, such that an annulus "A' is formed between the outer
diameter of the
inner tubular Ti and the inner diameter of the outer tubular T2. In some
cases, the annulus
may contain material, such as cement, barite, other sealing materials, mud
and/or debris.
in other cases, the annulus "A" may not have any material therein. When the
expansion tool
OK 600' reaches the desired location in the tubular T1, the hi-directional
boosters 624, 626,
628 are detonated to simultaneOtisly ignite opposing ends of the serially-
arranged column of
pellets 640 to form two shock waves that collide to create an amplified shock
wave that
travels radially outward to impact the inner tubular TI at a first location,
and expand at least a
portion of the wall of the tubular TI radially Outward, as shown in FIG. 3413,
without
perforating or cutting through the portion of the wall, to form a protrusion
"'P' of the tubular
Ti at the portion of the wail The protrusio11"P" extends into the annulus
between an
outer surface of the wall of the inner tubular Ti and an inner surface of a
wall of the outer
tubular T2. Note that the pipe dimensions shown in FIGS. 34.A to 34C are
exemplary and for
context, and are not limiting to the scope of the invention.
[0144] The protrusion 1)." may impact the inner wall of outer tubular T2 after
detonation of
the explosive pellets 640. in Some embodiments, the protrW.ion. "P" may
maintain contact
with the inner wall of the outer tubular T2 after expansion is completed. In
other
embodiments, there may be a. sinati space between the protrusion. 'II" and the
inner wall of
the outer tubular .12. Expansion of the tubular T I at the protrusion '1?" can
cause that portion
of the wall of the., tubular Ti to be work-hardened, resulting in greater
strength of the wall at
the protrusion "P". Embodiments of the methods of the present illy:ail-ion
show that the
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portion of the wall having, the protrusion "P" is not we4ened in particular,
the yield
strength of the tubular 11 increases at the protrusion "P", while the tensile
strength of the
tubular TI at the protrusion "P" decreases only nominally. Theretbre,
according to these
embodiments, expansion of the tubular T1 at the protrusion "P" thus
strengthens the tubular
Without breaching the tubular TI.
[0145] The magnitude of the protrusion ''P" can depend on several factors,
including the
length of the column of explosive pellets 640, the outer diameter of the
explosive pellets 640,
the amount of explosive material in the explosive pellets 640, the type of
explosive material,
the strength of the tubular T1, the thickness of the wall of the tubular Ti,
the hydrostatic
force bearing on the tubular Ti, and the clearance adjacent the tubular TI
being expanded,
i.e., the width of the annulus "A" adjacent the tubular Ti that is to be
expanded.
[0146] One way to manipulate the magnitude of the protrusion "P" is to control
the amount
of explosive force acting on the pipe or other tubular member TI, This cm be
done by
changing the number of pellets 640 aligned along the guide tube 616. For
instance, the
explosive force resulting from the ignition of a total. of ten pellets 640 is
larger than the
explosive three resui wig from the ignhion of a total of five similar pellets
640, As discussed
above, the length "LI" (see FIG. 34C) of the expansion of the wall of the
tubular T1 may be
about two times the length of the column of explosive pellets 640. Another way
to manipulate
the magnitude of the protnision '"P" is to use pellets 640 with different
outside diameters. The
expansion tool discussed herein can be used with a variety of different
numbers of pellets 640
in order to suitably expand the wall of pipes or other tubular members of
different sizes.
Determining a suitable amount of explosive force (evg., the number of pellets
640 to be
serially arranged on the guide tube 616), to expand the wall of a given
tubular T. in a
controlled manner, can depend on a variety of factors, including: the length
of the column of
explosive pellets 640, the outer diameter of the explosive pellets 640, the
material of the
tubular T1, the thickness of a wall of the tubular TI,, the inner diameter of
the tubular T1, the
outer diameter of the tubular T1, the hydrostatic force bearing on the tubular
III, the type of
the explosive (e_g., WAX, FINS) and the desired size of the protrusion "P" to
be formed in the
wall of the tubular TI,
[0147] The above method of selectively expanding at least a portion of a wall
of the tubular
Ti via an expansion tool may be modified to include determining the following
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PCT/US2021/064072
characteriOics of the tubular Ti :.a. material, of the tubular TI: a
thickness. Of a wan of the
tubular TI; an inner diameter of the tubular an
outer diameter of the tubular Ti;
hydrostatic force bearing on the tubular TI; and a size of a protrusion "P".
to be formed in the
.wail of the tubular Ti. Next, the explosive force necessary to expand,
without puncturing, the
wall of the tubular T1 to form the protrusion '`p", IS Calculated, or
determined via teging,
based on the above determined material characteristics.
[014S1 The determinations and calculation of the explosive force can be
performed via a
software program, and providing input, Which can then be executed on a
computer. Physical
hydrostatic testing of the explosive expansion charges yields data which may
be input to
develop computer models. The computer implements a central processing unit
(CPU) to
execute steps of the program. The program may be recorded on a computer-
readable
recording medium, such as a CD-ROM, or temporary storage device that is
removably
attached to the computer. Alternatively, the software program may be
downloaded from a
remote server and stored internally on a memory device inside the computer.
Based on the
necessary force, a requisite number of eXplosiVe pellets 640 to be serially
added to the guide
tube 06 of the expansion toot is determined. The requisite number of explosive
pellets 640
can be determined via the software program diseussed above,
[01491 The requisite number of explosive pellets 640 is then serially added to
the guide tube
610: After loading, the loaded expansion tool can be positioned within the
tubular II, with
the last pellet 640 in the column being located adjacent the detonation window
634. Next, the
expansion tool can be actuated to ignite the pellets 640, resulting in a shock
wave, as
discussed above, that expands the wall of the tubular Ti radially outward,
without perforating
or cutting through the wall, to form the protrusion "P". The protrusion "P'
can extend into the
annulus "A" between an outer surtke of the tubular Ti and an inner surface of
a wall of
another tubular T2,
[0150] In a test conducted by the inventors Ong the dual end firing explosive
column tool
600 to radially expand a pipe timing a 6.4 centimeter (25 inch) wall
thickness, an inner
diameter of 2-2,9 centimeters (9.0 inches) and an outer diameter of 35,6
centimeters (14.0
inches), the expansion resulted in a radial protrusion measuring 45.7
centimeters (1$.0
inches) in diameter, That is, the., outer diameter of the pipe., increased
from 35.6 centimeters
(14.0 inches) to 45,7 centimeters (18,0 incheS) at the protrusion. The
protrusion is a gradual
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expansion of the wa11 of the tubular TI The tnOre gradual expansion allows a
greater
expansion of the tubular T1 prior to exceeding the elastic strength of the
tubular Ti, and
failure of the tubular TI (te., the tubular being breeched).
[0151) The column of :eXplOsiVe pellets 640 can comprise a predetemyined or
requisite)
amount of explosive material sufficient to expand at least a portion of the
wall of the pipe or
other tubular into a protrusion extending outward into an annulus adjacent the
wall of the
pipe or other tubular. it is important to note that the expansion can be a
controlled outward
expansion of the wall of the pipe or other tubular, .which does not cause
puncturing,
breaching, penetrating or severing of the wall of the pipe or other tubular.
The annulus may
be reduced between an outer surface of the wall of the pipe or other tubular
.and an outer Wall
of another tubular or a formation,
[01.52] The protrusion "P" creates a ledge or barrier into the. annulus that
helps seal that
portion of the wellbore during Plug and abandonment operations in an oil well.
For instance,
a sealant, such as cement or other sealing material, mud and/or debris, may
exist in the
annulus "A" on the ledge or barrier created by the protrusion The
embodiments above
involve using one column of explosive pellets 640 to selectiVely expand a
portion of wall of
a tubular into the annulus. One option is to use two or more columns of
explosive pellets 640.
The explosive columns may be spaced at respective expansion lengths which, as
noted
previously, on vary as a function of the length Of the eXplOsive column unique
to each
application. After the =first protrusion is forined by the first explosive
colutinn, the additional
explosive column is detonated at a desired location, to expand the wall of the
tubular TI at a
second lk.)cation that is spaced from the first location and in a direction
parallel to an axis of
the expansion tool, to create a pocket outside the tubular TI between the
first and second
locations. The pocket is: thus created by sequential detonations of explosive
columns. In
another embodiment, the pocket may be formed by simultaneous detonations of
explosives
columns, For instance, two explosive Columns may be spaced from each other at
first and
Second locations, respectively, along the length of the tubular TL The lWo
explosive columns
are detonated simultaneously at the first and second locations to expand the.
wall of the
tubular Ti at the first and second locations to create the pocket outside the
tubular TI,
between the first and second locations.
CA 03203289 2023-05-26
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i01531 Whether one or multiple columns Of pxplosiNv pellets 640 are utilized,
the method
may further include setting a plug 19 below the deepest selective expansion
zone, and then
shooting perforating puncher charges through the wall of the inner tubular TI
above the top
of the shallowest expansion zone, sO that there can be communication ports 21
from the inner
diameter of the inner tubular Ti to the annulus "4" between the inner tubular
Ti and the
outer tubular TZ as shown in FIG. 34C. Cement 23, or other sealing material,
may then be
pumped to create a seal in the inner diameter of the inner tubular TI and in
the annulus "A"
through the communication ports 21 between the inner tubular Ti and the outer
tubular T2, as
shown in FIG, 34C, The cement 2:3 is viscuS enough that, even if there is only
a
ledge/restriction (formed by the protrusion po, the cement 23 should be slowed
do101 long
enough to set up and seal, When the cement 23 is pumped into the annulus
any and all
material, (e.g,, cement, mud, debris), Will likely help effect the seal. One
reason multiple
columns of explosive pellets 640 may be used is the hope that if a seal is not
achieved in the
annulus "A" at the first ledge/restriction (formed by the protrusion P1), the
seal may be
provided by the additional ledge/restriction (formed by the additional
protrusion). If the seal
in the annuluS "-A" cannot be effected, the operator must cut the inner
tubular T1 and retrieve
it to the surface, and then go through the same plug and pump cement procedure
for the Outer
tubular T2, Those procedures can be expensive.
[0154] The methods discussedõherein have involved selectively expanding a wall
of tubular
while the tubular is inside of a wellbore. A variation of the embodiments
discussed herein
includes a method of selectively expanding a wail of tubular outside of the
wellbore before
the tubular is inserted into the wellbore. This variation may be carried out
with the various
expansion tools discussed herein. The various expansion tools discussed herein
can be used to
selectively expand the wall of tubular outside of the wellbore. The amount of
explosive
material used in this variation may be based upon the physical aspects of the
tubular, the
nature and conditions of the wellbore in Which the tubular will subsequently
be inserted, and
upon the type Of flinction the selectively expanded tubular is to perfOrin in
the wellbore, The
selective expansion of the tubular may (kCiti, for example, at a facility
offsite from the
location of the actual wellbore. The selectively expanded tubular may be
inspected to confirm
dimensional aspects of the expanded tubular, and then be transported to the
wellsite for
insertion into the wellbore.. IFOr instance, a method of selectively
expanding, a wall of a
tubular may involve positioning an expansion tool 'within the tubular, wherein
the expansion
tool contains an amount of explosive material for producing an explosive force
sufficient to
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expand, without puncturing, the wall of the tubular. Next, the expansIon, loot
may be actuated
to expand the wall Of the tubular radially Outward, without petfottiting Or
tutting through the
wall of the tubular, to :font a protrusion that extends outward from the
central bore of the
tubular. The selectively expanded tubular may then be subsequently inserted
into a v,ellbore.
[015.51 Although several preferred embodiments have been illustrated in the
=OnIpanying
drawings and describe in the foregoing specification, it will be understood by
those of skill in
the art that additional embodiments, modifications and alterations may be
constructed from
the principles disclosed herein. These various embodiments have been described
herein with
respect to selectively expanding a "pipe" or a 'tubular." Clearly, oiller
embodiments of the
tool of the present invention may be employed for selectively expanding any
tubular good
including, but not limited to, pipe, tubing, produCtiOnicaSing liner andiOr
casing. Accordingly,
use of the term "tubular" in the following claims is defined to include and
encompass all
forms of pipe, tube, tubing, casing, liner, and similar mechanical elements.
47
