Disintegrating and adapting metallic sealing and method for producing it
Abstract
The seal comprises a metal composite comprising a cellular nanomatrix comprising a metallic nanomatrix material, a metal matrix disposed within the cellular nanomatrix and a disintegration control agent, an inner seal surface, and an outer seal surface disposed radially to the inner seal surface. The seal can be obtained by combining a metal matrix powder, a disintegration control agent, and a metal nanomatrix material to form a composition; densifying the composition to form a densified composition; sintering the densified composition; and pressing the sintered composition to form a seal.

Term
6.5 yearsleft in the term
Expires 4 April 2033.
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21 claims: 2 independent, 19 dependent
- 1Zastrzeżenia patentowe 1. Ulegające rozpadowi i dopasowujące się uszczelnienie metaliczne zawierające:kompozyt metaliczny, w którego skład wchodzi: nanomatryca komórkowa zawierająca metaliczny materiał nanomatrycy;oraz osnowa metaliczna umieszczona w nanomatrycy komórkowej;pierwszą powierzchnię uszczelniającą;oraz drugą powierzchnię uszczelniającą umieszczoną naprzeciw pierwszej powierzchni uszczelniającej, przy czym ulegające rozpadowi i dopasowujące się uszczelnienie metaliczne, znamienne tym, że kompozyt metaliczny ponadto zawiera środek kontrolujący rozpad rozmieszczony w osnowie metalicznej, osnowę metaliczną zawierającą wiele rozproszonych cząstek, oraz środek kontrolujący rozpad, który zawiera kobalt, miedź, żelazo, nikiel, wolfram lub kombinację zawierającą co najmniej jeden z powyższych;ilość osnowy metalicznej wynosi 50% wag. do 95% wag., ilość środka kontrolującego rozpad wynosi 0,25% wag. do 15% wag., oraz ilość materiału nanomatrycy metalicznej wynosi 10% wag. do 50% wag., każdorazowo w przeliczeniu na masę uszczelnienia, oraz uszczelnienie tworzy uszczelnienie metal-metal po przyłożeniu siły ściskającej.
- 2Uszczelnienie według zastrz. 1, w którym pierwsza powierzchnia uszczelniająca jest umieszczona wewnątrz uszczelnienia, a druga powierzchnia uszczelniająca jest umieszczona radialnie względem pierwszej powierzchni uszczelniającej na zewnątrz uszczelnienia.
- 3Uszczelnienie według zastrz. 1, w którym osnowa metaliczna zawiera glin, żelazo, magnez, mangan, cynk lub kombinację zawierającą co najmniej jeden z powyższych.
- 4Uszczelnienie według zastrz. 1, w którym metaliczny materiał nanomatrycy zawiera glin, ko- balt, miedź, żelazo, magnez, nikiel, krzem, wolfram, cynk, ich tlenki, ich azotki, ich węgliki, ich związki międzymetaliczne, ich cermet lub kombinację zawierającą co najmniej jeden z powyższych.
- 5Uszczelnienie według zastrz. 1, zawierające ponadto cząstkę dodatku zawierającą metal, węgiel, tlenek metalu, azotek metalu, węglik metalu, związek międzymetaliczny, cermet lub kombinację zawierającą co najmniej jeden z powyższych.
- 6Uszczelnienie według zastrz. 5, w którym ilość cząstek dodatku wynosi około 0,5% wag. do około 25% wag., w przeliczeniu na masę uszczelnienia.
- 7Uszczelnienie według zastrz. 1, zawierające ponadto dławik w zewnętrznej powierzchni uszczelniającej.
- 8Uszczelnienie według zastrz. 7, zawierające ponadto elastomer umieszczony w dławiku.
- 9Uszczelnienie według zastrz. 8, w którym elastomer zawiera kauczuk butadienowy, kauczuk butylowy, chlorosulfonowany polietylen, kauczuk epichlorohydrynowy, kauczuk etylenowo-propylenowo-dienowy, kauczuk etylenowo-propylenowy, elastomer fluorowy, kauczuk nitrylowy, elastomer perfluorowy, kauczuk poliakrylowy, polichloropren, poliizopren, kauczuk polisiarczkowy, sanifluor, kauczuk silikonowy, kauczuk styrenowo-butadienowy lub kombinację zawierającą co najmniej jeden z powyższych.
- 10Uszczelnienie według zastrz. 1, w którym uszczelnienie jest uszczelnieniem tymczasowym.
- 11Uszczelnienie według zastrz. 1, w którym uszczelnienie wykazuje procentowe wydłużenie wynoszące od około 10% do około 75%.
- 12Uszczelnienie według zastrz. 1, w którym uszczelnienie wykazuje granicę plastyczności od około 15 ksi do około 50 ksi (103 MPa - 345 MPa).
- 13Uszczelnienie według zastrz. 1, w którym uszczelnienie wykazuje wytrzymałość na ściskanie od około 30 ksi do około 80 ksi (207 MPa - 552 MPa).
- 14Uszczelnienie według zastrz. 1, w którym uszczelnienie charakteryzuje się odpornością temperaturową do 1000°F (540°C).
- 15Uszczelnienie według zastrz. 1, w którym uszczelnienie może ulec rozpadowi w kontakcie z płynem.
- 16Uszczelnienie według zastrz. 1, w którym płyn obejmuje solankę, kwas mineralny, kwas organiczny lub kombinację zawierającą co najmniej jeden z powyższych.
- 17Uszczelnienie według zastrz. 1, w którym uszczelnienie wykazuje szybkość rozpadu od około 1 mg/cm 2 /h do około 10 000 mg/cm 2 /h. PL237 181 Β1
- 18Wyrób zawierający uszczelnienie według zastrz. 1, znamienny tym, że wyrób stanowi korek do szczelinowania, korek mostkujący (szczelinowania), uszczelkę lub zawór klapowy.
- 19Sposób do tymczasowego uszczelnienia elementu, który to sposób obejmuje:doprowadzenie ciśnienia dla odkształcenia uszczelnienia według zastrz. 1;znamienny tym, że stosuje się dopasowanie uszczelnienia do przestrzeni z utworzeniem tymczasowego uszczelnienia;oraz doprowadzenie do kontaktu tymczasowego uszczelnienia z płynem w celu dezintegracji tymczasowego uszczelnienia.
- 20Sposób według zastrz. 19, w którym tymczasowe uszczelnienie stanowi uszczelnienie metal-metal.
- 21Sposób według zastrz. 19, w którym pierwsza powierzchnia uszczelniająca stanowi wewnętrzną powierzchnię uszczelniającą, a druga powierzchnia uszczelniająca stanowi zewnętrzną powierzchnię uszczelniającą umieszczoną radialnie od wewnętrznej powierzchni uszczelniającej.
Independent claims21
128 paragraphs in 4 sections, as filed
Description of the invention
The present invention relates to a disintegrating and conforming metallic seal, an article comprising a seal, and a method for temporarily sealing an element.
Wellbore designs, including oil and gas wells, CO2 storage boreholes, etc., often use borehole components or tools which, due to their function, require only a limited life, significantly shorter than the well's useful life. After a component or tool has fulfilled its function, it must be removed or disposed of to restore the original fluid path size during hole use, including hydrocarbon production, CO2 capture or storage, etc. Disposal of components or tools may be accomplished by grinding or drilling the component, or tools from the borehole, which is generally a time-consuming and costly operation. The industry is always open to new systems, materials and methods that eliminate component or tool removal from the borehole, avoiding the use of these types of milling and drilling operations.
The prior art publication US 2011/0214881 discloses a flow control system having a plurality of plugs. In this embodiment, the plugs contain a material that has a substantially continuous cellular nanomatrix containing the nanomatrix material, a plurality of dispersed particles dispersed in the cellular nanomatrix, and a solid-state binding layer extending throughout the cellular nanomatrix between the dispersed particles.
Another prior art document US 2006/186602 discloses annular sealing elements. They have inner and outer surfaces of deformable metal joined at their ends defining an interior volume that is completely filled with the deformable plastic material.
A disintegrating and conforming metallic seal containing a metallic composite which includes: a cellular nanomatrix containing the metallic nanomatrix material; and a metallic matrix embedded in a cellular nanomatrix; the first sealing surface; and a second sealing surface opposed to the first sealing surface.
The disintegrating and conforming metal seal of the present invention is characterized in that the composite metal further comprises a disintegration controlling agent disposed in the metal matrix, a metal matrix containing a plurality of dispersed particles, and a disintegration controlling agent that includes cobalt, copper, iron, nickel, tungsten or a combination comprising at least one of the above wherein the amount of the metal matrix is 50 wt.%. % to 95 wt.%, the amount of disintegration control agent is 0.25 wt.%. % to 15 wt.%, and the amount of the metallic nanomatrix material is 10 wt.%. % by weight, each based on the weight of the seal, and the seal forms a metal-to-metal seal when a compressive force is applied.
For a disintegrating and conforming metallic seal, it is preferred that the first sealing surface is positioned within the seal and the second sealing surface is positioned radially with respect to the first sealing surface outside the seal. It is also preferred that the metallic matrix comprises aluminum, iron, magnesium, manganese, zinc, or a combination including at least one of the above. Furthermore, it is preferred that the metallic material of the nanomatrix comprises aluminum, cobalt, copper, iron, magnesium, nickel, silicon, tungsten, zinc, their oxides, their nitrides, their carbides, their intermetallic compounds, their cermets or a combination containing at least one of the above.
For a disintegrating and conformable metal seal, it is preferred that it further comprises an additive particle comprising a metal, carbon, metal oxide, metal nitride, metal carbide, intermetallic compound, cermet, or a combination including at least one of the above. Preferably, the amount of additive particles is about 0.5 wt.%. up to about 25 wt.%, based on the weight of the seal.
In a further preferred embodiment, the disintegrating and conforming metallic seal further comprises a gland in the outer sealing surface. Preferably it further comprises an elastomer disposed in the gland. It is also preferred that the elastomer comprises butadiene rubber, butyl rubber, chlorosulfonated polyethylene, epichlorohydrin rubber, ethylene-propylene-diene rubber, ethylene-propylene rubber, fluoro elastomer, nitrile rubber, perfluoro elastomer, polyacrylate rubber, polyisoprene rubber, polyacrylate rubber.
Compound, sanifluoride, silicone rubber, styrene butadiene rubber, or a combination including at least one of the above.
In another preferred embodiment, the seal is a temporary seal. It is also preferred that the seal exhibit an elongation percentage of from about 10% to about 75%. In addition, it is preferred that the seal has a yield strength of about 15 ksi to about 50 ksi (103 MPa - 345 MPa) and it is preferred that the seal has a compressive strength of about 30 ksi to about 80 ksi (207 MPa - 552 MPa), and it is preferred that the seal has a temperature resistance of up to 1000 ° F (540 ° C).
According to the invention, it is advantageous if the seal can break on contact with the fluid. It is also preferred that the fluid comprises brine, a mineral acid, an organic acid, or a combination comprising at least one of the above. It is further preferred that the seal has a disintegration rate of from about 1 mg / cm<sup>2</sup>/ h to about 10,000 mg / cm<sup>2</sup>/ h.
The invention also relates to an article comprising a seal, characterized in that the article is a fracturing plug, a bridging (fracturing) plug, a gasket or a flap valve.
Another object of the invention is a method for temporarily sealing an element, the method comprising applying pressure to deform the seal. The method for temporarily sealing an element according to the invention is characterized in that it applies the seal to the space to form a temporary seal; and contacting the temporary seal with a fluid to disintegrate the temporary seal.
The temporary seal is preferably a metal-to-metal seal. Preferably, the first sealing surface is an inner sealing surface and the second sealing surface is an outer sealing surface radially from the inner sealing surface.
The following description should not be taken as limiting the scope of the invention in any way. Referring to the accompanying drawings, similar elements have been similarly numbered:
Fig. 1 is a cross-sectional view of a collapsible tubular anchoring system;
Fig. 2 is a cross-sectional view of the disintegrating metal composite;
Fig. 3 is a photomicrograph of an exemplary embodiment of a disintegrating metal composite as disclosed herein;
Fig. 4 is a cross-sectional view of the composition used to make the disintegrative metal composite shown in Fig. 2;
Fig. 5A is a micrograph of pure metal without a cellular nanometer;
Fig. 5B is a photomicrograph of a metal matrix disintegrating metal composite with a cellular nanomatrix;
Fig. 6 is a plot of weight loss versus time for various disintegrating metal composites including a cellular nano matrix showing selectively matched disintegration rates;
Fig. 7A is an electron micrograph of a fracture surface of a compact made of pure Mg powder;
Fig. 7B is an electron photomicrograph of the fracture surface of an exemplary embodiment of a disintegrating metal composite with a cellular nanomatrix as described herein;
Fig. 8 is a graph of the compressive strength of a metallic composite with a cellular nanomatrix as a function of the weight percent of a component (Al2O3) of the cellular nanomatrix;
Fig. 9A is a cross-sectional view of an embodiment of the collapsible tubular anchoring system in the borehole;
Fig. 9B is a cross-sectional view of the system of Fig. 9A in a fixed position;
Fig. 10 is a cross-sectional view of a frusto-conical disintegrating member;
Fig. 11 is a cross-sectional view of the disintegrating lower fastener;
Figures 12A, 12B and 12C show a perspective view, a cross-sectional view and a top view of the disintegrating sleeve, respectively;
Figures 13A and 13B are perspective and cross-sectional views, respectively, of a disintegrating seal;
PL 237 181 B1
Fig. 14 is a cross-sectional view of another embodiment of a disintegrating tubular anchoring system;
Fig. 15 is a cross-sectional view of the collapsible tubular anchoring system of Fig. 14 in a predetermined position;
Fig. 16 is a cross-sectional view of another embodiment of a disintegrating tubular anchoring system;
Fig. 17 is a cross-sectional view of another embodiment of a disintegrating seal with an elastomeric backup ring in a disintegrating tubular anchorage system; while
Figures 18A and 18B are cross-sectional and perspective views of another embodiment of the disintegrating seal, respectively.
Herein, a detailed description of one or more embodiments of the disclosed device and method is provided by way of example, and not limitation, with reference to the figures.
The inventors have discovered that a high-strength, high-ductility, although fully disintegrating, tubular anchor system can be made of materials that selectively and in a controlled manner disintegrate upon contact with certain drilling fluids or in response to altered conditions. Such a disintegrating system contains components which are prone to selective corrosion and exhibit selectively selectable disintegration rates and selectively selectable material properties. In addition, the disintegrating system comprises components which exhibit differing compressive and tensile strengths and which include a seal (to form e.g. metal-to-metal seal), cone, deformable sleeve (or sliding elements) and bottom fitting. The term "disintegrating" as used herein refers to a material or component that may wear, corrode, degrade, dissolve, deteriorate, or otherwise be removed. It should be understood that the use of the term "decays" or any form thereof (eg, "decay") in this specification includes the given meaning.
An embodiment of the disintegrating tubular anchoring system is shown in Fig. 1. The disintegrating tubular anchoring system 110 includes a seal 112, a frustoconical member 114, a sleeve 116 (shown here as a slip ring), and a lower fitting 118. The system 110 is configured as such. that the longitudinal movement of the frustoconical member 114 with respect to the sleeve 116 and the seal 112 causes the sleeve 116 and seal 112 to radially modify, respectively. While in this embodiment the radial variations are outward, in alternative embodiments the radial variations may be in other directions, such as radially inward. Additionally, the longitudinal dimension D1 and the thickness T1 of the wall portion of the seal 112 may change when a compressive force is applied thereto. The seal 112, the frustoconical member 114, the sleeve 116, and the lower fitting 118 (i.e. components of system 110) disintegrate and contain a metallic composite. The metallic composite consists of a metallic matrix embedded in a cell nanomatrix and a disintegration controlling agent.
In one embodiment, the disintegration control agent is contained in the metal matrix. In another embodiment, the disintegration control agent is contained outside the metal matrix. In yet another embodiment, the disintegration control agent is contained within the metal matrix as well as outside the metal matrix. The metallic composite also includes a cellular nanomatrix, which includes the metallic material of the nanomatrix. The disintegration controlling agent may be contained in the cellular nanomatrix within the metallic material of the nanomatrix. An exemplary metal composite and a method used to produce a metal composite are disclosed in U.S. Patent Applications Serial Numbers 12 / 633,682, 12 / 633,688, 13 / 220,832, 13 / 220,822, and 13 / 358,307, each of these patent applications being incorporated by reference. the entirety of the present description by reference.
For example, the metal composite may be a powder compact as shown in Figure 2. The metal composite 200 includes a cellular nanomat 216 that includes a nanomatrix material 220 and a metal matrix 214 (e.g., dispersed particles) comprising a core particle material 218 dispersed in the cell nanomatrix. 216. The particle core material 218 comprises nano-structured material. Such a metal composite containing a cellular nanomatrix with a metal matrix embedded therein is referred to as a controlled electrolytic material.
Referring to Figs. 2 and 4, the metal matrix 214 may include any suitable metallic particle core material 218 that includes the nanostructure as described herein.
PL 237 181 B1 document. In an exemplary embodiment, the metallic matrix 214 is formed from particle cores 14 (FIG. 4) and may contain an element such as aluminum, iron, magnesium, manganese, zinc, or a combination thereof as the nano-structured particle core material 218. More specifically, in an exemplary embodiment, the metal matrix 214 and the particle core material 218 may comprise various Al or Mg alloys as the nanostructured particle core material 218, including various precipitation hardening Al or Mg alloys. In certain embodiments, the core particle material 218 comprises magnesium and aluminum, wherein the aluminum is present in an amount from about 1 weight percent (wt.%) To about 15 wt.%, Particularly about 1 wt.%. % to about 10 wt.%, more specifically about 1 wt.%. % to about 5 wt.% based on the weight of the metal matrix with the balance being magnesium.
In an additional embodiment, precipitation hardening Al or Mg alloys are particularly useful as they can strengthen the metal matrix 214 by both nanostructuring and precipitation hardening by including molecular precipitates as described herein. The metallic matrix 214 and the particle core material 218 may also contain a rare earth element or a combination of rare earth elements. Examples of rare earth elements include Sc, Y, La, Ce, Pr, Nd, or Er. A combination containing at least one of the above rare earth elements may be used. The rare earth element, when present, may be present in an amount from about 5 wt.%. % or less, and in particular about 2 wt.%. or less, based on the weight of the metallic composite.
The metallic matrix 214 and the particle core material 218 may also include nano-structured material 215. In an exemplary embodiment, the nano-structured material 215 is a material with a grain size (e.g., sub-grain or crystallite size) that is less than about 200 nanometers (nm), particularly from about 10 nm to about 200 nm, and more particularly, the mean grain size is less than about 100 nm. The metal matrix nanostructure 214 may include large angle boundaries 227 which are typically used to define grain size, or small angle boundaries 229 that may exist as a substructure within a particular grain which are sometimes used to define crystallite size, or a combination thereof. It should be noted that the nanocell matrix 216 and the grain structure (nanostructured material 215 containing grain boundaries 227 and 229) of the metallic matrix 214 are distinct features of the metal composite 200. In particular, the nanocell matrix 216 is not part of the crystalline or amorphous portion of the metallic matrix 214.
The disintegration controlling agent is included in the metal composite 200 to control the disintegration rate of the metal composite 200. The disintegration controlling agent may be included in the metal matrix 214, the cellular nanomatrix 216, or a combination thereof. According to one embodiment, the disintegration control agent comprises a metal, fatty acid, ceramic particles, or a combination including at least one of the above, the disintegration control agent being placed among the controlled electrolytic material to vary the disintegration rate of the controlled electrolytic material. In one embodiment, the disintegration controlling agent is positioned in the cellular nanomatrix externally to the metal matrix. In a non-limiting embodiment, the disintegration control agent increases the disintegration rate of the metal composite 200. In another embodiment, the disintegration control agent reduces the disintegration rate of the metal composite 200. The disintegration control agent can be a metal, including cobalt, copper, iron, nickel, tungsten, zinc, or a combination. containing at least one of the following. In another embodiment, the disintegration control agent is a fatty acid, e.g. fatty acids containing 6 to 40 carbon atoms. Examples of fatty acids include oleic acid, stearic acid, lauric acid, hydroxystearic acid, behenic acid, arachidonic acid, linoleic acid, linolenic acid, ricinoleic acid, palmitic acid, montanic acid, or a combination including at least one of the above. In yet another embodiment, the disintegration control agent is ceramic particles, such as boron nitride, tungsten carbide, tantalum carbide, titanium carbide, niobium carbide, zirconium carbide, boron carbide, hafnium carbide, silicon carbide, niobium boron carbide, aluminum nitride, titanium nitride, zirconium nitride, tantalum nitride, or a combination including at least one of the above. Additionally, the ceramic particle may be one of the ceramic materials discussed below in relation to the reinforcing agent. Such ceramic particles have a size of 5 µm or less, especially 2 µm or less, and more particularly 1 µm or less. The disintegration control agent may be present in an amount effective to cause the metal composite 200 to disintegrate at a desired disintegration rate, particularly about 0.25 wt.%. % up to about 15 wt.%, in particular
% In general, about 0.25 wt.%. % to about 10 wt.%, in particular about 0.25 wt.%. to about 1 wt.% based on the weight of the metal composite.
In an exemplary embodiment, the cell nanomaterial 216 comprises aluminum, cobalt, copper, iron, magnesium, nickel, silicon, tungsten, zinc, their oxide, their nitride, their carbide, their intermetallic compound, a cermet thereof, or a combination including at least one of the above . The metal matrix may be present in an amount from about 50 wt. % to about 95 wt.%, especially about 60 wt.%. % to about 95 wt.%, and more particularly about 70 wt.%. up to about 95 wt.%, based on the weight of the seal. Moreover, the amount of the metal nanomatrix material is about 10 wt.%. % to about 50 wt.%, in particular about 20 wt.%. % to about 50 wt.%, more particularly about 30 wt.%. up to about 50 wt.%, based on the weight of the seal.
In another embodiment, the metal composite comprises secondary particles. As illustrated generally in Figures 2 and 4, the metal composite 200 may be formed using coated metal powder 10 and an additional or secondary powder 30, i.e. both powders 10 and 30 can have substantially the same molecular structure without containing identical chemicals. The use of additional powder 30 produces a metal composite 200 that also contains a greater number of dispersed secondary particles 234 as described herein, which are dispersed in the cell nanomat 216, and are also dispersed relative to the metal matrix 214. Thus, the dispersed secondary particles 234 come from the particles of the secondary powder 32 contained in the powder 10, 30. In an exemplary embodiment, the dispersed secondary particles 234 include Ni, Fe, Cu, Co, W, Al, Zn, Mn, Si, their oxide, their nitride, their carbide, their intermetallic compound, a cermet thereof, or a combination including at least one of the above.
Referring again to Fig. 2, the metal matrix 214 and the particle core material 218 may also include an additive particle 222. The additive particle 222 provides a dispersion enhancement mechanism for the metal matrix 214 and obstructs or serves to limit the movement of dislocation within individual metal matrix particles 214. In addition, the additive particle 222 may be included in the cell nanomaterial 216 to reinforce the metal composite 200. The additive particle 222 may be any suitable size, and in an exemplary embodiment, it may have an average particle size of from about 10 nm to about 1 micron, and more particularly from about 50 nm to about 200 nm. The size here refers to the largest linear dimension of the additive particle. The additive particle 222 may include any suitable particle form, including embedded particle 224, precipitated particle 226, or dispersion particle 228. The embedded particle 224 can include any suitable embedded particle, including a variety of hard particles. The embedded particle can include various particles of a metal, carbon, metal oxide, metal nitride, metal carbide, intermetallic compound, cermet, or a combination thereof. In an exemplary embodiment, the hard particles may include Ni, Fe, Cu, Co, W, Al, Zn, Mn, Si, their oxide, their nitride, their carbide, their intermetallic compound, a cermet thereof, or a combination including at least one of the above. The additive particle may be present in an amount from about 0.5 wt.%. % to about 25 wt.%, in particular about 0.5 wt.%. % to about 20 wt.%, more particularly about 0.5 wt.%. up to about 10 wt.% based on the weight of the metal composite.
In the metal composite 200, the metal matrix 214 dispersed in the cellular nanomaterial 216 may have an equiaxed structure within the substantially continuous cellular nanomatrix 216, or may be substantially elongated along an axis such that the individual metallic matrix particles 214 have, for example, a flattened or elongated shape. In the case where the metal matrix 214 comprises substantially elongated particles, the metal matrix 214 and the cellular nanomatrix 216 may be continuous or discontinuous. The particle size of the metal matrix 214 may be from about 50 nm to about 800 gm, particularly about 500 nm to about 600 gm, and more particularly about 1 gm to about 500 gm. Depending on the particle size, monodisperse or polydisperse systems may arise, and the particle size distribution may be unimodal or bimodal. The size here refers to the largest linear dimension of the particle.
In Fig. 3, a microphotograph of an exemplary embodiment of a metallic composite is shown. The metallic composite 300 includes a metal matrix 214 that includes particles containing the core particle material 218. In addition, each metal matrix particle 214 is embedded in a cellular nanomatrix 216. At this point, the cellular nanomatrix 216 has been shown as a white lattice that essentially surrounds the matrix constituent particles. metallic 214.
PL 237 181 B1
According to an exemplary embodiment, the metal composite is formed from a combination of, for example, powder components. As illustrated in Fig. 4, the powder 10 comprises powder particles 12 comprising a core 14 of a particle with a core material 18 and a metallic coating layer 16 with a coating material 20. Such powder components can be selected and configured to compact and sinter to provide a metal composite 200 that is it is light (i.e. exhibits a relatively low density), high strength, and selectively and controlled removable, e.g. by disintegration, from the borehole in response to a change in properties in the borehole, including selectively and controlled disintegration (e.g., being characterized by selectively selected disintegration rate curve) in a suitable drilling fluid, including the various drilling fluids disclosed herein.
The nanostructure may be formed in the core 14 of the particle used to form the metal matrix 214 by any suitable method, including a strain induced nanostructure which may be obtained by grinding the powder in a ball mill to obtain a 14 particle core, and in particular by cryogenic grinding of the powder. (e.g. ball milling in a ball milling medium at cryogenic temperature or in a cryogenic fluid such as liquid nitrogen) to obtain particle cores 14 used to form the metal matrix 214. Particle cores 14 may be formed as nano-structured material 215 by any suitable method such as for example, by milling or cryogenically milling the molten powder particles from the materials described herein. Particle cores 14 can also be formed by mechanical alloying of pure metal powders with desired amounts of various alloying elements. Mechanical alloying involves grinding in a ball mill, including cryogenic grinding, of these powdery components to mechanically coat and mix the components and form particle cores 14. In addition to forming a nanostructure as described above, ball milling, including cryogenic grinding, may contribute to the strengthening of the solid core solution in the core 14 of the particle and the core material 18, which in turn may contribute to the strengthening of the solid solution of the metallic matrix 214 and particle core material 218. Strengthening of the solid solution may result from the ability to mechanically mix or from a higher concentration of interstitial atoms or substitute solute atoms in the solid solution than is possible according to certain equilibria in the phase of the alloy components, thus creating an obstacle or serving to limit the movement of dislocations within the particle, which in turn provides a hardening mechanism in the particle core 14 and the metallic matrix 214. The particle core 14 can also be formed with a nanostructure (grain boundaries 227, 229) by methods including, for example, condensation in an inert gas, chemical vapor phase condensation, deposition by pulsed electron gun, plasma synthesis, crystallization of amorphous solids, electrolytic deposition and significant plastic deformation. The nanostructure may also exhibit a high dislocation density, such as a dislocation density of between about 10<sup>17</sup> m<sup>-2</sup> and about 10<sup>18</sup> m<sup>-2</sup>which can be two to three orders of magnitude more than similar alloy materials deformed by traditional methods such as cold rolling.
The substantially continuous cell nano-matrix 216 (see Fig. 3) and the nano-matrix material 220 are formed of metallic coating layers 16 by pressing and sintering a plurality of metallic coating layers 16 with a greater number of powder particles 12, such as by cold isostatic pressing (CIP). ), hot isostatic pressing (HIP) or dynamic forging. The chemical composition of the nanomaterial material 220 may be different from that of the coating material 20 due to diffusion effects associated with sintering. The metal composite 200 also includes a plurality of particles composing the metal matrix 214 including the core particle material 218. Metal matrix 214 and core material 218 particles correspond to and are formed from more particle cores, and core material 18 from more particles 12 of powder when metallic layers of shell 16 are sintered together to form a cell nanomat 216. Chemical composition of material 218 The core of the particle may also be different from the composition of the core material 18 due to diffusion effects associated with sintering.
As used herein, the term "cell nanomaterial" 216 does not mean the major component of the powder compact, but rather refers to a minor component or components, either on a weight or per volume basis. This is a distinctive feature of most matrix composite materials in which the matrix comprises a major component based on weight or volume. The term "substantially continuous on" is used
The cell matrix "is intended to describe the extensive, regular, continuous, and interconnected nature of the distribution of the material 220 nanomaterial within the metal composite 200. As used herein, the term" substantially continuous "characterizes the stretching of the material 220 nanomat throughout the entire metal composite 200. such that it extends between and surrounds substantially all of the metallic matrix 214. "Substantially continuous" is used to indicate that complete continuity and regular alignment of the cellular nanomatrix 220 around individual matrix metal particles 214 is not required. For example, defects in the coating layer 16 on core 14 particles for certain powder particles 12 can bridge the particle cores 14 during sintering of the metal composite 200, resulting in the formation of localized discontinuities within the cell nano matrix 216, although in other parts of the powder compact the cell nano matrix 216 is substantially continuous and characterized by the structure described herein. In contrast, for substantially elongated metallic matrix 214 particles (i.e., non-aligned shapes), such as formed by extrusion, the term "substantially discontinuous" is used to denote this incomplete continuity and breakage (e.g., fracture or separation) of the nanomatrix. around each metal matrix particle 214, such as may be in a predetermined direction of extrusion. As used herein, the term "cellular" is used to indicate that the nanomatrix defines a network of generally repeating, interconnected, compartments or cells of the nanomaterial material 220 that encompass and also interconnect the metal matrix 214. As used herein, the term "nanomatrix" is used to describe the size or scale of the matrix, in particular the thickness of the matrix between adjacent matrix metal particles 214. The metallic coating layers that are sintered together to form a nanomatrix are themselves coating layers with a thickness on the nanometer scale. Since the cell nanarray 216 at most locations, unlike the intersection of more than two metal matrix particles 214, generally involves the mutual diffusion and bonding of two coating layers 16 of adjacent powder particles 12 having a nanometer thickness, the formed cell nanarray 216 also has a thickness on the nanometer scale (e.g. . approximately twice the thickness of the coating layer as described herein) and is thus described as a nanomatrix. Moreover, the use of the term "metal matrix" 214 does not mean the minority component of the metal composite 200, but rather it refers to the major component or components, either on a weight or volume basis. The use of the term metallic matrix is intended to represent the discrete and discrete distribution of the particle core material 218 within the metallic composite 200.
Built-in particle 224 may be incorporated by any suitable method, including, for example, ball milling or cryogenic milling of the hard particles together with the core particle material 18. Precipitated particle 226 can include any particle that can be precipitated within the metal matrix 214, including precipitated particles 226 according to the phase equilibrium of the constituents of the materials of interest, particularly metal alloys, and their relative amounts (e.g. precipitation hardening alloy), including those that may be precipitated due to non-equilibrium conditions that can occur when an alloy component that has been forced into a solid alloy solution above its phase equilibrium limit, as is known during alloying mechanical, it is limited sufficiently to activate the diffusion mechanisms that enable precipitation. Dispersion particles 228 may include nanometer scale particles or element clusters resulting from the formation of particle cores 14, such as associated with grinding in a ball mill, including components of the grinding medium (e.g., balls) or grinding fluid (e.g., liquid nitrogen), or the core surfaces of the particles 14 themselves (e.g., metal oxides or nitrides). The dispersion particles 228 may contain an element such as, for example, Fe, Ni, Cr, Mn, N, O, C, H, and the like. The additive particles 222 may be positioned anywhere in connection with the particle cores 14 and the metal matrix 214. In an exemplary embodiment, the additive particles 222 may be disposed within or on the surface of the metal matrix 214 as illustrated in FIG. 2. In another exemplary embodiment, the plurality of additive particles 222 are disposed on the surface of the metal matrix 214 as well as may be distributed within the cellular nanomatrix 216 as illustrated in Fig. 2.
Likewise, the dispersed secondary particles 234 may be formed from coated or uncoated secondary particles 32 of the powder, such as by dispersing the secondary particles 32 of the powder with the particles 12 of the powder. In an exemplary embodiment, the coated secondary particles 32 of the powder may be coated with a coating layer 36, which is the same as the coating layer 16 of the powder particles 12, such that the coating layers 36 also form part of the nanomatrix.
216. In another exemplary embodiment, the secondary powder particles 232 may be uncoated, and the dispersed secondary particles 234 are deposited within the nanomatrix 216. The powder 10 and additional powder 30 may be mixed to form a homogeneous suspension of dispersed particles 214 and dispersed particles. secondary particles 234, or to form a non-homogeneous suspension of these particles. The dispersed secondary particles 234 may be formed from any suitable additional powder 30 different from powder 10, either due to differences in the composition of the particle core 34 or coating layer 36 or both, and may include any of the materials disclosed herein for use as a secondary powder. 30, which are different from the powder 10 that was selected to form the powder compact 200.
In one embodiment, the metallic composite optionally comprises a reinforcing agent. The reinforcing agent increases the strength of the metallic composite material. Examples of reinforcing agents include ceramics, polymer, metal, nanoparticles, cermet, and the like. In particular, the reinforcing agent may be silica, glass fiber, carbon fiber, carbon black, carbon nanotubes, borides, oxides, carbides, nitrides, silicides, borides, phosphides, sulfides, cobalt, nickel, iron, tungsten, molybdenum, tantalum, titanium, chromium , niobium, boron, zirconium, vanadium, silicon, palladium, hafnium, aluminum, copper, or a combination including at least one of the above. According to one embodiment, ceramics and metal are combined to form a cermet, e.g. tungsten carbide, cobalt nitride and the like. Examples of strengthening agents include, but are not limited to, magnesium oxide, mullite, thorium dioxide, beryllium oxide, uranium dioxide, spinels, zirconium oxide, bismuth oxide, aluminum oxide, magnesium oxide, silica, barium titanate, cordierite, boron nitride, tungsten carbide, tantalum carbide. , titanium carbide, niobium carbide, zirconium carbide, boron carbide, hafnium carbide, silicon carbide, niobium boron carbide, aluminum nitride, titanium nitride, zirconium nitride, tantalum nitride, hafnium nitride, niobium nitride, boron nitride, silicon nitride, titanium boride, chromium boride, zirconium boride, tantalum boride, molybdenum boride, tungsten boride, cerium sulphide, titanium sulphide, magnesium sulphide, zirconium sulphide, or a combination containing one or more of the foregoing. Non-limiting examples of polymers acting as a reinforcing agent include polyurethanes, polyimides, polycarbonates, and the like.
In one embodiment, the enhancing agent is a particle size of about 100 microns or less, particularly about 10 microns or less, and more particularly 500 nm or less. In another embodiment, the fibrous reinforcement agent may be combined with a molecular reinforcement agent. It is believed that the inclusion of a reinforcing agent can increase the strength and fracture toughness of the metal composite. While not wishing to be bound by theory, it is believed that the finer (i.e., smaller in size) particles can produce a more durable metal composite as compared to larger sized particles. Moreover, the shape of the reinforcing agent can be varied and includes a fiber, a sphere, a rod, a tube, and the like. The enhancer may be present in an amount from 0.01 wt% (wt%) to 20 wt%, in particular 0.01 wt%. % up to 10 wt.%, more particularly 0.01 wt.%. up to 5 wt.%
In the production of the decomposed component of the anchoring system (e.g. a seal, frustoconical member, sleeve, lower connector, and the like) comprising a metal composite, the process comprising combining a metal matrix powder, a disintegration control agent, a metal nanomatrix material, and optionally a reinforcing agent to form a composition; thickening the composition to form a thickened composition; sintering the thickened composition; and compressing the sintered composition to form a disintegrable system component. The components of the composition can be mixed, ground, blended, and the like to form a powder 10 as shown, for example, in Fig. 4. It should be noted that the metallic nanomatrix material is a coating material disposed on a metallic matrix powder which, when compacted and sintered, forms cellular nanomatrix. A compact may be formed by compressing (i.e., compacting) the composition under pressure to form a fresh compact. The fresh compact may then be compacted at a pressure of from about 15,000 psi to about 100,000 psi (1,020-68,000 atm), particularly about 20,000 psi to about 80,000 psi (1,360-5440 atm), and more particularly about 30,000 psi. psi to about 70,000 psi (2,040-4760 atm) at a temperature from about 250 ° C to about 600 ° C, and more particularly about 300 ° C to about 450 ° C, to form a powder compact. Pressing to form a powder compact may include in-mold compression. The powder compact may further be machined to impart a useful shape to the powder compact. Alternatively, the powder compact may
The material should be pressed into a useful shape. The machining may include cutting, sawing, ablation, milling, planning (face machining), turning, drilling, and the like, using, for example, a milling machine, table saw, lathe, gouging machine, electrical discharge generator, and the like.
The metal matrix 200 can be of any desired shape or size, including a cylindrical billet, bar, plate, toroid, or other form that can be machined, formed, or otherwise used to make useful manufacturing items, including a variety of drilling tools and components. Pressing is used to produce a disintegrating component of the anchoring system (e.g. seals, frustoconical member, sleeve, lower link, and the like) from the sintering and pressing processes used to make the metal composite 200 by deforming the powder particles 12, including the particle cores 14 and the coating layers 16, to provide full density and the desired macroscopic the shape and size of the metallic composite 200, as well as its microscopic structure. Morphology (e.g. the alignment or substantially elongation) of the individual metallic matrix particles 214 and the cellular nanomaterial 216 of the particle layers results from sintering and deformation of the powder particles 12 as they are compacted and undergo mutual diffusion and deformation to fill the intermolecular spaces of the metallic matrix 214 (Fig. 2). Sintering temperatures and pressures may be selected to ensure that the density of the metal composite 200 reaches substantially its full theoretical density.
The metal composite shows favorable properties for use in, for example, downhole conditions. In one embodiment, the composite metal component of the disintegrating anchorage system has an initial shape that can be inserted into the depth and, in the case of a seal and sleeve, can then be deformed under pressure. The metal composite is strong and ductile with an elongation percentage of from about 0.1% to about 75%, particularly about 0.1% to about 50%, and more particularly about 0.1% to about 25%, based on the initial size of the component being subjected to. breakdown of the anchoring system. The metal composite has a yield strength of from about 15 kilograms per square inch (ksi) to about 50 ksi (103-345 MPa), and more particularly about 15 ksi to about 45 ksi (103-310 MPa). The compressive strength of the metal composite is from about 30 ksi to about 100 ksi (207-690 MPa), and more particularly about 40 ksi to about 80 ksi (276-552 MPa). The components of the disintegrating anchor system may have the same or different material properties such as percent elongation, compressive strength, tensile strength, and the like.
Unlike elastomeric materials, the components of the disintegrating anchor system disclosed herein that include a metallic composite can withstand temperatures up to about 1200 ° F (650 ° C), in particular up to about 1000 ° F (540 ° C), and more in detail around 800 ° F (430 ° C). The disintegrating anchorage system is temporary in that the system may selectively and tailor-made disintegrate in response to contact with the drilling fluid or changing conditions (e.g., pH, temperature, pressure, time, and the like). In addition, the components of the disintegrating anchoring system may have the same or different rates of disintegration or reactivity with the drilling fluid. Examples of drilling fluids include brine, mineral acid, organic acid, or a combination including at least one of the above. The brine can be, for example, seawater, production water, fill (service) brine, or a combination thereof. The properties of the brine may depend on the nature and ingredients of the brine. For example, seawater contains numerous ingredients such as sulfates, bromides, and trace metals in addition to the usual halide-containing salts. On the other hand, the production water may be water extracted from a production reservoir (e.g. a hydrocarbon reservoir), recovered from the ground. Production water is also referred to as reservoir brine and often contains many components such as barium, strontium and heavy metals. In addition to the naturally occurring brines (seawater and production water), fill brine can be synthesized from fresh water by adding various salts such as KCI, NaCl, ZnCl2, MgCl2 or CaCl2 to increase the brine density, such as 10.6 lb. per gallon (1270 kg / m<sup>3</sup>) for CaCl2 brine. Backfill brines typically provide hydrostatic pressure optimized to counter seam pressures in the borehole. The brines above can be modified to contain additional salt. In one embodiment, the additional salt contained in the brine is NaCl, KCl, NaBr, MgCl2, CaCl2, CaBr2, ZnBr2, NH4Cl, sodium formate, cesium formate, and the like. Salt may be present in the brine in an amount from about 0.5 wt.%. % to about 50 wt.%, in particular from about 1 wt.%.
% To about 40 wt.%, More particularly from about 1 wt.%. % to about 25 wt.% based on the weight of the composition.
In another embodiment, the drilling fluid is a mineral acid, which may include hydrochloric acid, nitric acid, phosphoric acid, sulfuric acid, boric acid, hydrofluoric acid, hydrobromic acid, perchloric acid, or a combination including at least one of the above. In yet another embodiment, the drilling fluid is an organic acid, which may include a carboxylic acid, a sulfonic acid, or a combination including at least one of the above. Examples of carboxylic acids include formic acid, acetic acid, chloroacetic acid, dichloroacetic acid, trichloroacetic acid, trifluoroacetic acid, propionic acid, butyric acid, oxalic acid, benzoic acid, phthalic acid (including ortho-, meta-para- isomers), and the like similar. Examples of sulfonic acids include alkylsulfonic acid or arylsulfonic acid. Alkylsulfonic acids include, for example, methanesulfonic acid. Arylsulfonic acids include e.g. benzenesulfonic acid or toluenesulfonic acid. In one embodiment, the alkyl group may be branched or unbranched and may contain from one to about 20 carbon atoms, and may be substituted or unsubstituted. The aryl group may be alkyl substituted, i.e. may be an alkylaryl group, or may be attached to the sulfonic acid moiety via an alkylene group (i.e., aralkyl group). In one embodiment, the aryl group may be substituted with a heteroatom. The aryl group can contain from about 3 carbon atoms to about 20 carbon atoms and include a polycyclic ring structure.
The rate of disintegration (also referred to as the dissolution rate) of the metallic composite is from about 1 milligram per square centimeter per hour (mg / cm<sup>2</sup>/ h) to about 10,000 mg / cm<sup>2</sup>/ h, in particular about 25 mg / cm<sup>2</sup>/ h to about 1000 mg / cm<sup>2</sup>/ h, and more particularly about 50 mg / cm<sup>2</sup>/ h to about 500 mg / cm<sup>2</sup>/ h. The rate of disintegration varies depending on the composition and processing conditions of the metal composite produced.
Without wishing to be bound by theory, it is believed that the unexpectedly high rate of disintegration of the metal composite described herein is due to the microscopic structure defined by the metal matrix and the cellular nanomatrix. As discussed above, this type of microscopic structure is provided by the use of metallurgical treatment of the powder (e.g. (e.g. thickening and sintering) of the coated powders, the coating producing the nanocellular matrix and the powder particles producing the core material of the metallic matrix particles. It is believed that the immediate proximity of the cellular nanomatrix and the core material of the metallic matrix particles in the metallic composite creates plating sites that allow for a rapid and tailored breakdown of the metallic matrix. Such electrolysis sites are missing in single metals and alloys devoid of cell nanomatics. By way of illustration, Fig. 5A shows a compact 50 formed of magnesium powder. Although the compact 50 has particles 52 surrounded by particle boundaries 54, the particle boundaries function as physical boundaries between a substantially identical material (particles 52). For a change, fig. 5B shows an exemplary embodiment of a composite metal 56 (powder compact) having a metal matrix 58 that includes a particle core material 60 disposed in a cell nanomaterial 62. Composite metal 56 was formed from magnesium particles coated with alumina, whereby the metallurgical treatment of the powder produces the alumina coating 62, and the magnesium produces a metallic matrix 58 containing the core particle material 60 (magnesium). The cellular nanomatrix 62 represents not only a physical boundary, as the particle boundary 54 in Fig. 5A, aie also delineates the chemical boundary introduced between the adjacent core materials 60 of the metallic matrix particles 58. While the particles 52 and the particle boundary 54 of the compact 50 (FIG. 5A) do not contain galvanic sites, the metallic matrix 58 comprising the particle core material 60 in combination with the cellular nanomatrix 62 defines many galvanic sites. The reactivity of the plating sites depends on the compounds used in the metal matrix 58 and the cellular nanomatrix 62 and is a result of the treatment conditions applied to the metal matrix and the microscopic structure of the metal composite cell nanomatrix.
In addition, the microscopic structure of the metal composites described herein can be controlled by selecting the metallurgical treatment conditions of the powder and the chemicals used in the powders and coatings. Therefore, the rate of disintegration can be selectively adjusted, as illustrated for metal composites of different compositions in Figure 6, which shows a plot of weight loss versus time for various metal composites containing a cellular nanomatrix. In particular, fig. 6 shows the decay rate curves for four
Various metal composites (metal composite A 80, metal composite B 82, metal composite C 84 and metal composite D 86). The slope of each segment of each curve (separated by black circles in Figure 6) corresponds to the decay rates for each segment of the curve. Metal composite A80 shows two different rates of disintegration (802, 806). Metal composite B 82 shows three different disintegration rates (808, 812, 816). Composite C 84 shows two different rates of disintegration (818, 822) and Composite D 86 shows four different rates of disintegration (824, 828, 832 and 836). During the time represented by points 804, 810, 814, 820, 826, 830 and 834, the rate of decomposition of the metallic composite (80, 82, 84, 86) changes due to changes in conditions (e.g. pH, temperature, time, pressure, such as discussed above). The speed may increase (e.g., from speed 818 to speed 822) or decrease (e.g. going from 806 to 802) along the same decay curve. In addition, the disintegration rate curve may exhibit more than two rates, more than three rates, more than four rates, etc. depending on the microscopic structure and components of the metal composite. In this way, the decay rate curve can be selectively adjusted and distinguished from the curves for common metal alloys and pure metals without microscopic structure (i.e. metal matrix and cellular nanomatrix) of the metal composites described herein.
The microscopic structure of the metal composite governs not only the degradation rate behavior of the metal composite, but also affects the strength of the metal composite. Consequently, the metal composites described herein also exhibit selectively tweakable material strength (as well as other material properties) whereby the material strength varies depending on the processing conditions and materials used to manufacture the metallic composite. For illustration, Fig. 7A is an electron photomicrograph of the fracture surface of a compact formed from pure Mg powder, and Fig. 7B is an electron photomicrograph of the fracture surface of an exemplary embodiment of a metallic composite with a cellular nano-matrix as described herein. The microstructural morphology of an essentially continuous cell nanomatrix, which can be selected to provide reinforcement of the phase material, with a metallic matrix (containing the particle core material) provides the metal composites described herein with improved mechanical properties, including compressive strength and shear strength. as the resultant cell nanomaterial / metal matrix morphology can be manipulated to provide reinforcement through processes that are similar to traditional reinforcement mechanisms such as grain size reduction, solution hardening through the use of impurity atoms, precipitation hardening or aging, and strain hardening mechanisms. The cellular nanomaterial / metal matrix structure tends to limit the dislocation movement due to the multiple contact surfaces of the nanomaterial particles as well as the contact surfaces between discrete layers within the cellular nanomaterial material as described herein. This is reflected in the fracture behavior of these materials as illustrated in Figures 7A and 7B. In fig. 7A a compact made with uncoated pure Mg powder and subjected to a shear stress sufficient to cause rupture showed a grain break. In contrast, in Fig. 7B metal composite made with powder particles containing pure Mg powder particle cores to form a metallic matrix and Al-containing metallic coating layers to form a cell nanomatrix and subjected to a shear stress sufficient to cause rupture exhibited intercrystalline fracture and substantially higher stress to fracture as described in this document. As these materials have high strength, the core material and coating material can be selected to use low density materials or other low density materials such as low density metals, ceramics, glasses or carbon which would not otherwise provide the necessary strength characteristics for desired applications, including drilling tools and components.
To further illustrate the selectively tailored properties of the metal composite materials containing a cellular nanomatrix, Fig. 8 is a plot of the compressive strength of the metal composite with a cellular nanomatrix as a function of the weight percent of the component (Al2O3) of the cellular nanomatrix. Fig. 8 clearly shows the effect of changing the percentage by weight (wt%) i.e. thickness, aluminum oxide coatings for compressive strength at room temperature of a metallic composite with a cellular nanometer made of coated powder particles containing a multilayer (Al / Al2O3 / Al) coating layer
Metal on the pure Mg particle cores. In this example, the optimal strength was reached at 4 wt.%. of alumina, representing an increase of 21% compared to the value for 0 wt. alumina.
Thus, the metal composites described herein can be configured to provide a wide range of selectable and controllable corrosion or degradation behaviors, ranging from very low corrosion rates to extremely high corrosion rates, particularly corrosion rates that are as low as and higher than for powder compacts that do not contain cellular nanomatics, such as a compact formed from pure Mg powder, by the same densification and sintering processes as compared to those containing the dispersed pure Mg particles in the various cellular nanomatrixes described herein. Such metal composites 200 may also be configured to provide substantially improved properties over compacts formed from pure metal particles (e.g., pure Mg) that do not contain the nanometer coatings described herein. In addition, metal alloys (formed e.g. by casting a molten material or obtained by metallurgical treatment of a powder) without a cell nanomatrix also do not contain selectively customizable material and do not exhibit chemical properties like the metal composites described herein.
As mentioned above, the metal composite is used to produce articles that can be used as tools or instruments, e.g. in a downhole environment. In a particular embodiment, the article is a seal, a frustoconical member, a sleeve, or a bottom fitting. In another embodiment, a combination of these articles is used as a disintegrating tubular anchorage system.
Referring to Figs. 9A and 9B, an exemplary embodiment of the disintegrating tubular anchoring system disclosed at 510 is illustrated. The sealing system 510 includes a frustoconical member 514 (also referred to as a cone and shown individually in Fig. 10) including a first frustoconical portion 516 and a second frustoconical portion 520 which are tapered in opposite longitudinal directions relative to each other. Lower connector 570 (shown individually in Fig. 11) is positioned at the end of disintegrating system 510. Sleeve 524 (shown individually in Fig. 12) may radially expand in response to longitudinal movement toward the first frustoconical portion 516. Similarly, seal 528 (shown individually in Figures 13A and 13B) may expand radially in response to longitudinal movement toward the second frustoconical portion 520. One way to move the sleeve 524 and seal 528 relative to the frustoconical portion 516,520 is to compress the complete assembly longitudinally with an adjusting tool 558.
Seal 528 includes seat 532 with a surface 536 that tapers in this embodiment and receives a plug 578 that can seal against surface 536 of seal 528.
Seal seat 532 also includes a flange 544 which is sandwiched between seal 528 and the second frustoconical portion 520. Flange 544 has a wall 548 whose thickness is reduced due to the frustoconical surface 552 facing radially inward. wall 548 allows thinner portions to deform more easily than thicker portions. This can be beneficial for at least two reasons. First, the thinner wall portion 549 may deform as flange 544 is moved relative to the second frustoconical portion 520 to radially expand seal 528 to seal joint with structure 540. Second, thicker wall portion 550 should resist deformation. due to the pressure difference across it which arises when the plug (e.g., plug 578) is pressed against seat 532, for example during a machining operation. The conicity angle of the frustoconical surface 552 may be selected to match the conicity angle of the second frustoconical portion 520, thereby allowing the second frustoconical portion 520 to provide radial support to the flange 544, at least in regions in which they are in contact with each other.
The disintegrative tubular anchorage system 510 is configured to seat (i.e., anchor) and seal to a structure 540, such as a guide tube, housing, or a closed or open bore, for example, in a borehole in a formation in the ground when used in a related application. with the extraction of hydrocarbons and storage of carbon dioxide. The sealing and anchoring in the structure 540 allows the pressure exerted on the plug 578 to be increased in order to process the formations in the ground, as is the case, for example, during openings.
Of lining and acid treatment. In addition, seat 532 is positioned within seal 528 such that pressure exerted on the plug seated on seat 532 presses seal 528 against sleeve 524 to thereby improve both the sealing engagement of seal 528 with structure 540 and with frustoconical member 514. and increase the anchoring engagement of sleeve 524 with structure 540.
The sealing system 510 may be configured such that the sleeve 524 is anchored (secured in a predetermined position) to the structure 540 before sealing 528 is sealed to the structure 540, or that the seal 528 is sealed to the structure 540 before the sleeve 524 is anchored to the structure 540. The adjustment of which of the seal 528 and sleeve 524 connects first to the structure 540 may be made by using the relationship of the material properties (e.g. relative compressive strength) or the dimensional relationships between the components involved in the formation of the seal 528 as compared to the components involved in the positioning of the sleeve 524. Whether the sleeve 524 or the seal 528 is connected to the structure 540 first, the alignment can be set in response to orientate portions of the setting tool that positions the disintegrating tubular anchorage system 510. Damage to seal 528 can be minimized by reducing or eliminating the relative movement between seal 528 and structure 540 after seal 528 engages structure 540. In this embodiment, joining seal 528 to structure 540 prior to engaging sleeve 524 with structure 540 may achieve this goal.
Surface 536 of seat 532 extends longitudinally in front of sleeve 524 (as viewed in the direction of fluid flow that presses the plug against seat 532). Additionally, seal seat 536 may be positioned longitudinally above collar 544 of seal 528. This relative positioning allows pressure forces on the plug seated within surface 536 to further press seal 528 into seal engagement with structure 540.
The portion of flange 544 that deforms conforms to the second frustoconical portion 520 sufficiently to be radially supported therewith, whether or not the angles of taper match. The frusto-conical second portion 520 may have tapered angles of from about 1 ° to about 30 °, in particular about 2 ° to about 20 ° to facilitate radial expansion of the collar 544 and to allow for frictional forces between the collar 544 and the second portion to be formed. truncated cone 520, in order to maintain the positional relationship therebetween after the longitudinal forces that caused movement between them cease to apply. The first frustoconical portion 516 may also have conicity angles of from about 10 ° to about 30 °, in particular about 14 ° to about 20 ° for the same reasons as the second frustoconical portion 520. One or both of the frustoconical surfaces 552 and the other frustoconical portion 520 may have more than one taper angle, as illustrated herein, on the other frustoconical portion 520 where the apex 556 has a larger taper angle than has a taper angle. surface 520 farther from vertex 556. Having multiple taper angles gives operators greater control over the amount of radial expansion of flange 544 (and hence seal 528) per unit of longitudinal movement between flange 544 and truncated cone member 514. Taper angles, in addition to other variables, also provide additional control. over the longitudinal forces necessary to move the collar 544 relative to the frusto-conical member 514. Such control may allow the collar 544 of the seal 528 to expand in the collapsible tubular anchoring system 510 to position the seal 528 prior to expansion and alignment of the sleeve 224.
In one embodiment, an adjusting tool 558 is disposed along the length of the system 510 from the lower link 570 to the seal 528. The adjusting tool 558 may apply the loads needed to cause the frusto-conical member 514 to move relative to the sleeve 524. The adjusting tool 558 may have a pin 560 with a stop. 562 connected to one end 564 by a member 566 being damaged by excessive force. Stop 562 is positioned to contact bottom link 570. Plate 568 placed in contact with seal 528 to follow a predetermined path along plunger 560 (by means not shown here) toward stop 562, at bottom link 570 may press the truncated cone member 514 longitudinally against the sleeve 524. Adjustments may be made such that loads to break the failing member 566 by excessive force only occur after the sleeve 524 has been radially modified by a predetermined amount by the truncated cone member 514. After the failing member 566 is torn apart,
If excessive force is exerted, the stop 562 may separate from the mandrel 560, which, for example, allows the mandrel 560 and plate 568 to be retracted to the surface.
In accordance with one embodiment, surface 572 of sleeve 524 includes protrusions 574, which may be termed teeth, configured to engage wall 576 of structure 540 within which a pattern 510 that disintegrates when surface 572 is within a radially modified ( i.e. extended) configuration. This engagement serves to anchor the disintegrating system 510 to the structure 540 to prevent relative movement therebetween. While the structure 540 disclosed in this embodiment is tubular, such as a guide tube or borehole housing, it may be, for example, an open hole in a formation in the ground.
Fig. 9B shows the disintegrating system 510 after the setting tool 558 has been removed from the structure 540 after the disintegrating system 510 has been positioned. Here, the projections 574 of the sleeve 524 engage the wall 576 of the structure 540 to anchor the disintegrating system 510 therein. Additionally, seal 528 has been radially expanded to contact wall 576 of structure 540 on the outer surface of seal 528 due to compression of seal 528 by setting tool 558. Seal 528 deforms so that the length of seal 528 increases as the thickness decreases as seal 528 compresses. between the frusto-conical member 514 and the wall 576 of structure 540. Thus, the seal 528 forms a metal-to-metal seal with the frustoconical member 514 and a metal-to-metal seal against wall 576. Alternatively, seal 528 may deform to fill topographic features of wall 576, such as gaps, cavities, protrusions, and the like. Likewise, the ductility and tensile strength of the seal 528 allow deformation of the seal 528 to fill the topographic features of the frusto-conical member 514.
After aligning the disintegrating system 510 with the protrusions 574 of the sleeve 514, the plug 578 can be placed on the surface 536 of the seat 532. After the plug 578 is sealed to the seat 536, the pressure can be increased upstream to perform work such as fracturing a formation of earth or starting a drilling tool, used for example for the extraction of hydrocarbons.
In one embodiment, as shown in FIG. 9B, plug 578, e.g., a ball, contacts seat 532 of seal 528. Pressure is applied, e.g., hydraulically, to plug 578 to deform collar 544 of seal 528. Collar 544 deformation. causes wall 548 to elongate and seal to structure 540 (e.g. borehole housing) to form a metal-to-metal seal with the first frustoconical portion 516 of the frustoconical member 514 and to form another metal-to-metal seal with the structure 576. Here, the ductility of the metal composite allows the seal 528 to fill the space between structure 540 and truncated-cone member 514. At this point, the drilling operation can be performed and the plug 578 removed immediately after the operation is performed. Removal of plug 578 from seat 532 may occur by creating a pressure differential across plug 578 such that plug 578 is removed from seat 532 and extends from seal 528 and frusto-conical member 514. Then, any of the seal 528, the frustoconical member 514, the sleeve 524, or the bottom fitting 570 may disintegrate upon contact with the drilling fluid. Alternatively, prior to removing the plug 578 from the seat 532, the drilling fluid may contact and disintegrate the seal 528, and the plug 578 may then be removed from any of the remaining components of the disintegrating system 510. Degradation of the seal 528, truncated member 514, sleeve 524, or bottom fitting 570 is advantageous at least in part as the borehole flow path is restored without mechanically removing components of the disintegrating system 510 (e.g., by drilling or milling) or flushing waste out of the borehole. borehole. It should be noted that the disintegration rates of the disintegrating system 510 are independently selectively adjusted as discussed above, and that the seal 528, the frustoconical member 514, the sleeve 524, or the lower link 570 exhibit independently selectively adjusted material properties such as yield point and yield point. compressive strength.
In accordance with another embodiment, the collapsible tubular anchoring system 510 is configured to leave a through hole 580 with an inner radial dimension 582 and an outer radial dimension 584 defined by the largest radial dimension of the collapsible system 510 when positioned within structure 540. exemplary execution
The internal radial dimension 582 may be large enough for the plunger 560 of the setting tool 558 to pass through the system 510. The stop 562 of the setting tool 558 may be left in the structure 540 after the disintegrating system 510 has been positioned and the plunger 560 has been removed. be retrieved from structure 540 upon disintegration of system 510 to at least the point where stop 562 can pass through internal radial dimension 582. Thus, the component of the disintegrating system 510 may be substantially solid. By incorporating port 580 into the disintegration system 510, fluid may be circulated through the disintegration system 510 either downstream or upstream in structure 540 to disintegrate a component (e.g., sleeve).
In another embodiment, the disintegrating tubular anchoring system 510 is configured with an inner radial dimension 582 that is large with respect to the outer radial dimension 584. According to one embodiment, the inner radial dimension 582 is greater than 50% of the outer radial dimension 584, particularly greater than 60%, and more particularly greater than 70%.
The seal, frustoconical member, sleeve and lower fitting may have advantageous properties for use in, for example, a downhole environment, either in combination or separately. These components disintegrate and may be part of a completely disintegrating anchor system as described herein. In addition, these components exhibit the mechanical and chemical properties of the metal composite described herein. Thus, these components preferably selectively and appropriately disintegrate in response to contact with the fluid or to a change in conditions (e.g., pH, temperature, pressure, time, and the like). Exemplary fluids include brine, a mineral acid, an organic acid, or a combination including at least one of the above.
A cross-sectional view of an embodiment of a frustoconical member is shown in Fig. 10. As described above, a frustoconical member 514 includes a first frustoconical portion 516, a second frustoconical portion 520, and a tip 556. The taper angle of the frustoconical member 514 may vary along the outer surface 584 such that the frustoconical member 514 has a variety of cross-sectional shapes, including the truncated double-cone shape shown. Thus, the thickness of wall 586 may vary along the length of the frustoconical member 514, and the inside diameter of the frustoconical member 514 may be selected for a particular application. The truncated-cone member 514 may have various applications, such as in the collapsible tubular anchoring system described herein, and in any situation where a strong or collapsible truncated cone shape is useful. Examples of applications include a bearing, a flare flange joint, a valve stem, an o-ring, and the like.
A cross-sectional view of the lower connector is shown in Figure 11. The lower connector 700 has a first end 702, a second end 704, an optional thread 706, optional ports 708, an inner diameter 710, and an outer diameter 712. In one embodiment, the lower connector 700 is the end of the tool. (e.g., disintegrating system 510). In another embodiment, the lower link 700 is located at the end of the drill string. In one embodiment, the lower fastener 700 is used to secure the tools to the column. Alternatively, the lower link 700 may be used between tools or columns and may be included in the joint. The lower connector 700 may be used with the column and product, such as a bridge plug, a frac plug, a mud pump, a sealant, a pull-yaw wedge, and the like. In one non-limiting embodiment, first end 702 provides a contact surface, e.g., with a frustoconical member 514 and sleeve 524. Second end 704 contacts stop 562 of setting tool 558. Thread 706, if present, may be used to secure the bottom. connector 700 to the product. In one embodiment, frustoconical member 514 includes a threaded portion mating threads 706. In certain example embodiments, thread 706 is absent and inner diameter 710 may be a straight bored hole or may include tapered portions thereof. Through holes 708 can transmit fluid, e.g., brine, to disintegrate lower connector 700 or other components of the disintegrating system 510. The through-holes may also provide the attachment point for a failing member 566 when used in conjunction with an adjusting tool 558 or the like. It is contemplated that the lower link 700 may have a different cross-sectional shape than that shown in Figure 11. Exemplary shapes include a cone, ellipsoid, torus, sphere, cylinder, truncated shapes, and asymmetric shapes.
Tric, including a combination of the foregoing and the like. Moreover, lower link 700 may be solid or may have an inside diameter of at least 10% of the size of the outside diameter, in particular at least 50%, and more particularly at least 70%.
The sleeve is shown in Figs. 12A, 12B, and 12C in perspective, cross-section, and plan views, respectively. Sleeve 524 includes outer surface 572, protrusions 574 disposed on outer surface 572 and inner surface 571. Sleeve 524 acts as a slip ring with protrusions 574 as slides that engage a surface such as a housing wall or an open aperture as sleeve 524 radially expands in response to first contact of the first portion 573 of the inner surface 571 with a mating surface (e.g., a first mating surface). the frusto-conical portion 516 in Fig. 10). The projections 574 may circumferentially surround the entirety of the sleeve 524. Alternatively, the projections 574 may be separated, either symmetrically or asymmetrically, as shown in the top plan view of Fig. 12C. The shape of the sleeve 524 is not limited to the shape shown in Fig. 12. The sleeve, except for being a slip ring in the decaying tubular anchoring system illustrated in Fig. 9, it may find application to position numerous tools including a sealant, a "bridge plug" or a frac plug, or it may be placed in any environment in which it can be made. counteracting product slippage by engaging the sleeve projections on the mating surface.
In Figures 13A and 13B, seal 400 has an inner seal surface 402, an outer seal surface 404, seats 406, and surface 408 of seat 406. Surface 408 is configured (e.g., shaped) to receive a member (e.g. plug) to provide a force to the seal 400 to deform the seal such that the inner sealing surface 402 and outer sealing surface 404 form metal-to-metal seals with mating surfaces, respectively (not shown in Figs. 13A and 13B). Alternatively, compressive force is applied to the seal 400 by a frustoconical member and an adjusting tool positioned at opposite ends of the seal 400, as in Fig. 9A. In one embodiment, the seal 400 finds use in a downhole environment as a conformable, deformable, highly ductile, and disintegrating seal. In one embodiment, the seal 400 is a bridge plug, a seal, a flap valve, and the like.
In addition to being selective for corrosion, the seal described herein deforms in place to conform to the space in which it is positioned in response to an applied deposition pressure, which is a pressure sufficiently large to expand the seal radially or to reduce the thickness of the seal wall by increasing the length of the seal. Unlike many types of seals, e.g. an elastomeric seal, the seal described herein is obtained with a shape that corresponds to the mating surface to be sealed, e.g. a casing or truncated drill tool. In one embodiment, the seal is a temporary seal and has an initial shape that can be inserted into and then deformed under pressure to form a metal-to-metal seal that deforms to conform to the surface with which the seal contacts and fills. spaces (e.g. gaps) in the mating surface. To obtain sealing properties, the seal has an elongation percentage of from about 10% to about 75%, particularly from about 15% to about 50%, and more specifically from about 15% to about 25%, of the original size of the seal. The seal has a yield strength of from about 15 kilo pounds per square inch (ksi) to about 50 ksi (103 MPa - 345 MPa), and more particularly about 15 ksi to about 45 ksi (103-310 MPa). The compressive strength of the seal is from about 30 ksi to about 100 ksi (207-690 MPa), and more particularly about 40 ksi to about 80 ksi (276-552 MPa). Pressure up to about 10,000 psi (69 MPa), particularly about 9,000 psi (62 MPa), may be applied to deform the seal.
Unlike elastomeric seals, the composite metal seal described here is temperature resistant up to about 1200 ° F (650 ° C), in particular to about 1000 ° F (540 ° C), and more particularly about 800 ° F (430 ° C). The seal is temporary in the sense that the seal may selectively and tailored disintegrate in response to contact with the drilling fluid or changing conditions (e.g. pH, temperature, pressure, time and the like). Examples of drilling fluids include brine, mineral acid, organic acid, or a combination including at least one of the foregoing.
PL 237 181 B1
Since the seal cooperates with other components, e.g., a frustoconical member, a sleeve, or a lower connector, e.g., in the collapsible tubular anchoring system described herein, the properties of each component are selected in accordance with the appropriate or selectively selected material and chemical properties. These properties characterize the metal composite and the processing conditions under which the metal composite is formed that is used to manufacture such articles, i.e. components. Therefore, in one embodiment, the metallic composite of a component will be different from that of another component of the disintegrating system. In this way, the components exhibit independently selectively adjusted mechanical and chemical properties.
According to one embodiment, the sleeve and seal are deformed by the force imparted by the frustoconical member and the lower fastener. To achieve this result, the sleeve and seal exhibit a compressive strength less than the compressive strength of the lower linkage or frustoconical member. In another embodiment, the sleeve deforms before, after or simultaneously with deformation of the seal. The lower link or frustoconical member is believed to deform in some embodiments. In one embodiment, a component comprises a different amount of a reinforcing agent than the other component, where, for example, the higher strength component contains a greater amount of the reinforcing agent than the lower strength component. In a specific embodiment, the frustoconical member comprises a greater amount of reinforcing agent than contained in the seal. In another embodiment, the frustoconical member comprises a greater amount of reinforcing agent than contained in the sleeve. Likewise, the lower fitting may contain a greater amount of reinforcing agent than the seal or sleeve. In a particular embodiment, the frusto-conical member exhibits a compressive strength greater than the compressive strength of the seal or sleeve. In one embodiment, the frustoconical member has a compressive strength of 40 ksi to 100 ksi (276-690 MPa), in particular 50 ksi to 100 ksi (345-690 MPa). In another embodiment, the lower linkage has a compressive strength of 40 ksi to 100 ksi (276-690 MPa), in particular 50 ksi to 100 ksi (345-690 MPa). In yet another embodiment, the seal has a compressive strength of 30 ksi to 70 ksi (207-483 MPa), in particular 30 ksi to 60 ksi (207-414 MPa). In yet another embodiment, the sleeve has a compressive strength of 30 ksi to 80 ksi (207-552 MPa), in particular 30 ksi to 70 ksi (207-483 MPa). Thus, under the compressive force, either the seal will deform or the sleeve will deform before either the lower fastener or the frustoconical member is deformed.
Other factors that can affect the relative strength of the components include the nature and size of the reinforcing agent particles in each component. In one embodiment, the frustoconical member includes a reinforcement with a smaller particle size than the reinforcement means in the seal or sleeve. In yet another embodiment, the lower fitting comprises a reinforcing agent with a smaller particle size than the reinforcing agent in the seal or sleeve. In one embodiment, the frustoconical member comprises a reinforcing agent such as ceramic, metal, cermet, or a combination thereof, the particle size of the enhancing agent being from 10 nm to 200 gm, especially 100 nm to 100 gm.
Yet another factor influencing the relatively selectively selected material and chemical properties of the components are the components of the metal composite, i.e. the metallic nanomatrix of the cellular nanomatrix, the metal matrix distributed within the cellular nanomatrix, or the disintegration controlling agent. The compressive and tensile strengths and the rate of disintegration are determined by the chemical identity and the relative amount of these components. Thus, these properties can be controlled with the components of the metallic composite. According to one embodiment, a component (e.g., a seal, a frustoconical member, a sleeve, or a lower fitting) comprises a metallic matrix metal matrix that includes pure metal, and another component includes a metal matrix that includes an alloy. In another embodiment, the seal includes a metal matrix that includes pure metal and the frusto-conical member includes a metal matrix that includes an alloy. In an additional embodiment, the sleeve comprises a metallic matrix of pure metal. It is contemplated that the component may be functionally graded in that the metallic matrix of the metallic composite may contain both pure metal and an alloy exhibiting a relative gradient of either pure metal or alloy in the metallic matrix distributed throughout the component. Therefore, the value of the selectively selected properties varies depending on the location along the component.
PL 237 181 B1
In a particular embodiment, the rate of disintegration of a component (e.g., seal, frustoconical member, sleeve, or bottom fastener) is greater than the rate of disintegration of the other component. Alternatively, each component may exhibit substantially the same rate of disintegration. In a further embodiment, the sleeve exhibits a faster rate of disintegration than another component, e.g., a frustoconical member. In another embodiment, the disintegration controlling agent of a component (e.g., a seal, a frustoconical member, a sleeve, or the bottom fastener) is present in more than the other component. In another embodiment, the amount of disintegration control agent present in the sleeve is greater than in the other component. In one embodiment, the amount of disintegration control agent in the seal is greater than in the other component.
Figures 14 and 15 illustrate an alternate embodiment of the collapsible tubular anchoring system 1110. The disintegrating system 1110 includes a frustoconical member 1114, a sleeve 1118 having a surface 1122, a seal 1126 having a surface 1130, and a seat 1134 each component. It is made of a metallic composite and exhibits selectable mechanical and chemical properties as described herein. The primary difference between system 510 (FIG. 9) and system 1110 is the initial relative position of the seal and the frustoconical member.
The amount of radial modification that surface 1122 of sleeve 1118 undergoes is controlled by the distance that the frustoconical member 1114 is pressed into sleeve 1118. The frustoconical surface 1144 on the frustoconical member 1114 may wedge with the surface. truncated cone shape 1148 on sleeve 1118. Thus, the further the truncated member 1114 moves relative to sleeve 1118, the greater the radial modification of sleeve 1118. Likewise, seal 1126 is radially positioned to the truncated surface 1144 and is secured longitudinally with respect to sleeve 1118, therefore, the farther away the frusto-conical member 1114 will move with respect to the sleeve 1118 and the seal 1126, the greater the radial modification of the seal 1126 and surface 1130. The above structure allows the operator to determine the amount of radial surface modification 1122, 1130 after the array 1110 has been placed within the structure 1150.
Optionally, system 1110 may include a flange 1154 radially disposed between seal 1126 and a frustoconical member 1114 such that the radial dimension of flange 1154 is also modified by the frustoconical member 1114 in response to movement therefrom. Flange 1154 can have a frustoconical surface 1158 complementary to a frustoconical surface 1144 such that substantially the entire longitudinal extent of flange 1154 is simultaneously radially modified during movement of the frustoconical member 1114. Flange 1154 can be made of a metallic composite that is is other than composite in the seal 1126 or in the truncated cone member 1114. Thus, collar 1154 can maintain seal 1126 in an altered radial dimension, even if the truncated surface 1144 is later removed from contact with the frustoconical surface 1158, thereby keeping seal 1126 in sealing engagement with wall 1162 of structure 1150. This can be achieved. by selecting the metal composite of the collar 1154 to have a higher compressive strength than the composite of the seal 1126.
The disintegrating system 1110 further includes a contact surface 1136 on the frustoconical member 1114 sealingly with plug 1138. The disintegrating system also includes a recess 1166 (in the wall 1058) of the sleeve 1118 for receiving projections 1170 on the stop fingers 1174, which accessories come into contact with each other as soon as the setting tool 558 compresses the disintegrating system 1110 similar to the positioning of the disintegrating system 510. by setting tool 558 as shown in Fig. 9.
Fig. 16 shows another alternative embodiment of the collapsible tubular anchoring system indicated by 1310. The disintegrating system 1310 includes a first frustoconical member 1314, a sleeve 1318 positioned and configured to expand radially into an anchor with a structure 1322, illustrated herein as a wellbore in the ground 1326, in response to pressing against a frustoconical surface. 1330 of the first frustoconical member 1314. The collar 1334 may expand radially to seal with structure 1322 in response to pressing longitudinally against the second frustoconical member 1338 and includes a seat 1342 with a surface 1346 sealingly receiving a plug 1350 (shown in dashed lines) movable relative thereto. The socket 1342 is
This configuration and the position of surface 1346 relative to collar 1334 helps keep collar 1334 in a radially expanded configuration (clockwise in Figure 16) from collar 1334. as it has been extended) by minimizing the radial forces acting on the collar 1334 due to the pressure difference across the seat 1342 as it becomes plugged with a plug 1350.
For clarification, if surface 1346 were to be located above even a portion of the longitudinal extension of collar 1334 (and it is not), then pressure generated across plug 1350 seated on surface 1346 would create a pressure differential radially across that portion of collar 1334 located below surface 1346. This pressure difference would be determined by a greater pressure radially outside of collar 1334 than radially inside collar 1334, thereby producing radially inward forces on collar 1334. These radially inward forces, if large enough, would cause collar 1334 to radially deform. inwardly, potentially compromising the durability of the seal between collar 1334 and structure 1322 in the process. This situation is avoided in particular by placing the face 1346 in a suitable position relative to the collar 1334.
Optionally, the collapsible tubular anchoring system 1310 includes a seal 1354 radially positioned with respect to collar 1334 and configured to facilitate sealing of collar 1334 to structure 1322 by radially compressing therebetween as collar 1334 is radially expanded. The seal 1354 is manufactured from a metallic composite exhibiting lower compressive strength than the composite of the first frustoconical member 1314 to improve the tightness of the seal 1354 to both the collar 1334 and structure 1322. In one embodiment, seal 1354 exhibits lower compressive strength than collar 1334. .
Thus, in this embodiment, the disintegrating system 1310 may include a first frustoconical member 1314, a sleeve 1318, and an optional seal 1354. In the event that the seal 1354 is absent, the flange 1334 of the first frustoconical member 1314 may form a metal-to-metal seal. metal with housing or lining, or conform to the surface of an open hole. In certain example embodiments, the first frustoconical member 1314 comprises a functionally stepped metal composite such that the collar 1334 exhibits a lower compressive strength value than the remainder of the first frustoconical member 1314. In another embodiment, the collar 1334 exhibits a lower compressive strength than the flange 1334. second frusto-conical member 1338. In yet another embodiment, the second frustoconical member 1338 exhibits greater compressive strength than the seal 1354.
The components described herein can be extended with a variety of materials. In one embodiment, a seal, e.g., seal 528, may include a backup seal, such as elastomeric material 602 as shown in Figure 17. The elastomer may, for example, be an O-ring positioned in gland 604 on the face of seal 528. The elastomeric material includes, but is not limited to, for example butadiene rubber (BR), butyl rubber (IIR), chlorosulfonated polyethylene (CSM), epichlorohydrin rubber (ECH, ECO), ethylene propylene diene rubber (EPDM), rubber ethylene propylene (EPR), fluoro elastomer (FKM), nitrile rubber (NBR, HNBR, HSN), perfluorine elastomer (FFKM), acrylic rubber (ACM), polychloroprene (neoprene) (CR), polyisoprene (IR), polysulfide rubber (PSR), sanifluor, silicone rubber (SiR), styrene-butadiene rubber (SBR), or a combination including at least one of the above.
As described herein, components, e.g., a seal, can be used in a downhole environment, for example, to provide a metal-to-metal seal. In one embodiment, a method of temporarily sealing a wellbore component includes placing the component deep into the wellbore and applying pressure to deform the component. The component may include a seal, a frustoconical member, a sleeve, a bottom, or a combination including at least one of the above. The method also includes fitting the seal into the space to form a temporary seal, compressing the sleeve to engage the surface, and then contacting the component with the drilling fluid to disintegrate the component. The component comprises a metal composite as described herein, which includes a metal matrix, a disintegration control agent, a cell nanomatrix, and optionally, a reinforcing agent. A metallic composite of the seal forms the inner
The sealing surface and the outer sealing surface are disposed radially with respect to the inner sealing surface of the seal.
According to one embodiment, the process of insulating a structure includes placing the disintegrative tubular anchoring system described herein in the structure (e.g., tubular, pipe, tunnel, borehole (closed or spigot), and the like), radially modifying the sleeve to make contact with the surface. structure, and the radial modification of the seal to insulate the structure. The disintegrative tubular anchorage system may be brought into contact with a fluid to disintegrate e.g. a seal, a frustoconical member, a sleeve, a bottom fitting or a combination of at least one of the foregoing. The process may further include positioning the disintegrating anchorage system with the setting tool. Additionally, a plug can be placed on the seal. Isolating a structure can completely or significantly inhibit the flow of fluid through that structure.
Furthermore, the seal may take a wide variety of shapes and include other sealing surfaces in addition to the specific configuration shown in Figures 9 and 13-16. In another embodiment, referring to Figures 18A and 18B, an embodiment of the seal 100 disclosed herein is illustrated . The seal 100 includes a metal composite, a first sealing surface 102 and a second sealing surface 104 opposed to the first sealing surface 102. The metallic composite includes a metal matrix embedded in a cellular nanomatrix, a disintegration controlling agent, and optionally a reinforcing agent. The seal 100 can be any shape and will conform in place, under pressure, to a surface to form a temporary seal that can selectively break in response to fluid contact. In this embodiment, the seal 100 is annular in shape with an outer diameter 106 and an inner diameter 108. In some embodiments, the sealing surface may be a first surface 102, a second surface 104, an outer diameter 106, an inner diameter 108, or a combination including at least one of the above.
While variations of the disintegrative tubular anchorage system have been described comprising several components in total, it is contemplated that each component may be used separately and independently as an article. In addition, any combination of components may be used together. Moreover, the components can be used on the surface or in a downhole environment.
While one or more embodiments have been illustrated and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been illustrated only, without limiting its scope. The embodiments given herein may be implemented independently or in combination.
Any ranges disclosed herein are taken together with the endpoints, and these endpoints can be independently combined. The plural is intended to include both the singular and the plural as modified thereby, thus including at least one of these terms (e.g., the term dye (s) includes at least one dye). "Optional" or "optionally" means that the event or circumstance described later may or may not occur, and that the description includes instances where the event occurs and instances in which it does not. The term "combination" as used herein includes blends, mixtures, alloys, reaction products, and the like. All sources are hereby incorporated by reference.
As used herein, terms like "one", "certain", etc. in the context of the description of the invention (especially in the context of the following claims) are to be interpreted as including both the singular and the plural, unless otherwise indicated or clearly contrary to the context. "Or" means "and / or". Furthermore, it should further be noted that the terms "first", "second" and the like as used herein do not imply order, amount (such that more than one, two, or more than two elements may be present), or validity, but are rather they are used to distinguish one element from another. When used in connection with an amount, the term "about" includes the indicated value and has a context meaning (eg, including the error value associated with the measurement of the specified amount).
Contents4
16 sheets
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8 Sheet 9 Sheet 10 Sheet 11 Sheet 12 Sheet 13 Sheet 14 Sheet 15 Sheet 16
21 members in 9 offices
Priority claims2
| Document | Office | Kind | Date |
|---|---|---|---|
| 201213466311 | United States of America | A | |
| 2013035262 | United States of America | W |
Members21
| Document | Office | Kind | |
|---|---|---|---|
| CA2872404A1 | Canada | A1 | |
| CA2953874A1 | Canada | A1 | |
| US2013300066A1 | United States of America | A1 | |
| WO2013169418A1 | World Intellectual Property Organization (WIPO) | A1 | |
| AU2013260077A1 | Australia | A1 | |
| CO7111254A2 | Colombia | A2 | |
| CN104285032A | China | A | |
| MX2014013544A | Mexico | A | |
| PL410368A1 | Poland | A1 | |
| RU2014149137A | Russian Federation | A | |
| CA2872404C | Canada | C | |
| US9605508B2 | United States of America | B2 | |
| AU2013260077B2 | Australia | B2 | |
| AU2017201833A1 | Australia | A1 | |
| US2017138479A1 | United States of America | A1 | |
| RU2627779C2 | Russian Federation | C2 | |
| AU2017201833B2 | Australia | B2 | |
| CN104285032B | China | B | |
| CA2953874C | Canada | C | |
| US10612659B2 | United States of America | B2 | |
| PL237181B1This record | Poland | B1 |
Numbers
- Publication
- 237181
- Application
- 410368
Titles2
- English
- Disintegrable and conformable metallic seal, article containing the seal, and method for temporarily sealing an element
- Polish
- Ulegające rozpadowi i dopasowujące się uszczelnienie metaliczne, wyrób zawierający uszczelnienie oraz sposób do tymczasowego uszczelnienia elementu
Classification
- CPC, 22
- B22F5/106
- E21B33/1208
- E21B33/1204
- E21B33/134
- B22F5/10
- B22F1/054
- B22F1/10
- B22F1/07
- C22C32/00
- C22C1/10
- B22F7/06
- C22C33/02
- B22F2998/10
- B22F3/16
- E21B33/1212
- F16J15/28
- E21B33/12
- B22F3/02
- B22F5/006
- B22F7/008
- E21B33/128
- F16J15/0806
- IPC, 6
- E21B33 12
- E21B23 06
- B22F1 054
- B22F1 07
- B22F1 10
- C22C1 10