Patent Publication Number: US-11662185-B2

Title: Amorphous shaped charge component and manufacture

Description:
PRIORITY CLAIM/CROSS REFERENCE TO RELATED APPLICATION(S) 
     This Patent Document is a divisional of U.S. Non-Provisional patent application Ser. No. 14/229,400, entitled “Amorphous Shaped Charge Component And Manufacture”, which claims priority under 35 U.S.C. § 119 to U.S. Provisional App. Ser. No. 61/806,785, entitled “Materials for Oilfield Shaped Charges and Guns”, filed on Mar. 29, 2013, and to U.S. Provisional App. Ser. No. 61/808,385, entitled “Perforating Tools and Components”, filed on Apr. 4, 2013. Each of these applications are incorporated herein by reference in its entirety for all purposes. 
    
    
     BACKGROUND 
     Exploring, drilling and completing hydrocarbon and other wells are generally complicated, time consuming and ultimately very expensive endeavors. As a result, over the years well architecture has become more sophisticated where appropriate in order to help enhance access to underground hydrocarbon reserves. For example, as opposed to wells of limited depth, it is not uncommon to find hydrocarbon wells exceeding 30,000 feet in depth. Furthermore, as opposed to remaining entirely vertical, today&#39;s hydrocarbon wells often include deviated or horizontal sections aimed at targeting particular underground reserves. 
     While such well depths and architecture may increase the likelihood of accessing underground hydrocarbon reservoirs, other challenges are presented in terms of well management and the maximization of hydrocarbon recovery from such wells. For example, during the life of a well, a variety of well access applications may be performed within the well with a host of different tools or measurement devices. However, providing downhole access to wells of such challenging architecture may require more than simply dropping a wireline into the well with the applicable tool located at the end thereof. Indeed, a variety of isolating, perforating and stimulating applications may be employed in conjunction with completions operations. 
     In the case of perforating, different zones of the well may be outfitted with packers and other hardware, in part for sake of zonal isolation. Thus, wireline or other conveyance may be directed to a given zone and a perforating gun employed to create perforation tunnels through the well casing. Specifically, shaped charges housed within the steel gun may be detonated to form perforations or tunnels into the surrounding formation, ultimately enhancing recovery therefrom. 
     The profile, depth and other characteristics of the perforations are dependent upon a variety of factors in addition to the material structure through which each perforation penetrates. That is, the jet formed by the detonation of a given shaped charge may pierce steel casing, cement and a variety of different types of rock that make up the surrounding formation. However, characteristics of different components of the shaped charge itself may determine the characteristics of the jet and ultimately the depth, profile and overall effectiveness of each given perforation as described below. 
     Among other components, a shaped charge generally includes a case, explosive pellet material and a liner. Thus, detonation of the explosive within the case may be utilized to direct the liner away from the gun and toward the well wall as a means by which to form the noted jet. Therefore, understandably, the characteristics of the jet are largely dependent upon the behavior of the liner and other shaped charge components upon detonation. For example, a solid copper or zinc liner may be utilized to generate a jet of considerable stretch with a head or tip that travels at 5-10 times the rate of speed as compared to the speed at the tail. Depending on the casing thickness, formation type and other such well-dependent characteristics, this type of liner is generally of notable effectiveness in terms of achieving substantial depth of penetration. 
     Unfortunately, a solid metal liner of the general type described above faces limitations in terms of the actual effectiveness of the penetration. For example, as described above, the perforation is a tunnel into the formation from which hydrocarbons may be extracted. However, a solid metal liner is prone to penetrate the formation in a manner that often leaves a slug of material lodged within the perforation. Thus, even where the perforation is of notable depth, it is often largely obstructed. Further, as the solid liner material begins to stretch and break up, it begins to tumble resulting in a loss of coherence and penetrating character. 
     In order to avoid such issues with solid liners, a crystalline powder liner may instead be utilized. For example, a crystalline base material may be mixed with a binding agent such as copper or lead and pressed into a liner component for assembly into a shaped charge. Thus, upon detonation of the shaped charge, a perforating jet will emerge from a crystalline powder material that readily disintegrates as opposed to emerging from a solid liner that is prone to leave behind a slug within the perforation. 
     Unfortunately, while the crystalline powder liner is not as prone to leave behind an occlusive slug, it is also not as prone to develop a jet of notable stretch or effectiveness in terms of perforating depth. That is, given the near immediate disintegration of the liner, its stretch, density distribution and other factors that might enhance depth are limited. Ultimately, this leaves the perforating gun operator with the undesirable choice between utilizing a shaped charge that may result in a perforation that is compromised by a slug versus one that may result in a perforation that is limited in terms of penetration depth. 
     SUMMARY 
     An embodiment of the present disclosure provides a shaped charge for use with a perforating gun in forming a perforation into a formation at a well wall with a jet. The shaped charge comprises a case, an explosive pellet accommodated by the case, and a liner of an amorphous-based material tailored to enhance the jet in forming the perforation. The liner is formed by a three dimensional print manufacturing application. 
     Another embodiment of the present disclosure provides a method comprising the steps of (a) deploying a perforating gun into a well to a target location adjacent a formation, and (b) detonating a shaped charge within a body of the gun at the location to generate a jet of enhanced character for tunneling a perforation into the formation. The shaped charge comprises a case accommodating an explosive pellet adjacent an amorphous-based material liner to support the enhanced character. In the method, one of the liner, the case, the shaped charge, the body of the perforating gun, or the loading tube of the perforating gun is formed as part of a three dimensional print manufacturing application. 
     Another embodiment of the present disclosure provides a multi-material three dimensional print method of manufacturing a shaped charge. The method comprises printing a case of a first material, printing an explosive pellet of a second material, and printing a liner of a third material. The printing of the case, explosive and liner takes place as part of a three dimensional print manufacturing application. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a side cross sectional view of an embodiment of a shaped charge incorporating a liner of amorphous material. 
         FIG.  2 A  is an enlarged view of the amorphous material liner and surrounding architecture taken from  2 - 2  of  FIG.  1   , highlighting the amorphous material structure. 
         FIG.  2 B  is an enlarged view of a conventional crystalline pressed powder liner and surrounding architecture, highlighting the crystalline material structure. 
         FIG.  3    is an overview of an oilfield with a well having a gun disposed therein for forming a perforation with the shaped charge of  FIG.  1   . 
         FIG.  4 A  is a side cross-sectional view of the shaped charge of  FIG.  1    forming a deep penetrating jet directed at a wall of the well of  FIG.  3   . 
         FIG.  4 B  is a side cross-sectional view of an alternate shaped charge forming a wide jet directed at the wall of the well of  FIG.  3   . 
         FIG.  4 C  is a side cross-sectional view of another embodiment of a shaped charge forming a tailored morphology jet directed at the wall of the well of  FIG.  3   . 
         FIG.  5    is a side cross-sectional view of the shaped charge of  FIG.  4 C  being formed during a three dimensional print manufacturing application. 
         FIG.  6    is a flow-chart summarizing an embodiment of forming and utilizing shaped charges incorporating amorphous materials. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments are described with reference to certain downhole perforating applications in vertical cased well environments. In particular, wireline deployed applications utilizing a shaped charge assembly system are detailed. However, other forms of deployment and well architectures may take advantage of the shaped charge assembly system as detailed herein. For example, multi-zonal wells may benefit from such a system during stimulation operations. Regardless, so long as shaped charge components take advantage of amorphous materials, such as an amorphous liner, significant benefit may be realized in the perforating application. 
     Referring now to  FIG.  1   , a side cross sectional view of an embodiment of a shaped charge  100  is shown. The charge  100  utilizes a liner  101 , at least a portion of which is primarily and/or exclusively of an amorphous material. That is, the entire liner  101  may be of such a material or have a segment or portion that is of such a material. Regardless, the amorphous material portion may be referred to herein as an “amorphous-based” material. For example, as described in further detail below, the entire liner  101 , or a predetermined portion thereof, may be of a silicon, metallic or other suitable glass with a variety of different fillers or additives incorporated therein. Regardless, as also detailed further below, a liner  101  of such an amorphous-based material may be utilized to enhance the stretch of a jet  400  during perforating in a well  380  such that substantial depth of a perforation  425  may be attained (see also  FIGS.  3  and  4 A ). Further, the amorphous nature of the liner  101  may substantially remove the possibility of liner material forming a slug that might undesirably block an end  427  of the perforation  425  (see  FIG.  4 A ). 
     Continuing with reference to  FIG.  1   , in addition to the noted liner  101 , the shaped charge  100  includes a case  150  that accommodates an explosive pellet material  175 . The explosive pellet  175  is located between the liner  101  and the case  150  with the case  150  being made up of a robust material such as steel or zinc. Thus, once a fuse  110  is triggered to ignite the pellet  175 , the material of the liner  101  may breach the void space  125  of the charge  100  and extend beyond a seal  155  of the case  150  to form a jet (e.g.  400  of  FIG.  4 A ). In theory, the longer the jet  400  or the greater the stretch (S), the deeper the penetration or perforation  425  (again see  FIG.  4 A ). As detailed further below, such characteristics may be achieved through use of a liner  101  that is of an amorphous-based material. 
     The case  150  may be formed by conventional machining such as computer, numeric code or forging. The amorphous-based material liner  101  may also be separately machined from a solid bar. Additionally, the liner  101  may be formed by stamping, pressing or other suitable techniques. Regardless, the separately formed case  150  and liner  101  may be assembled together with the pellet  175  sandwiched therebetween and the case seal  155  placed thereover. However, in an embodiment detailed further below with reference to  FIG.  5   , any one of the case  150 , pellet  175  or liner  101  components may be formed via emerging three dimensional print techniques. Indeed, all three components may be simultaneously formed as part of the same three dimensional printing application. Once more, in addition to the use of an amorphous-based material for the liner  101 , an amorphous-based material may also be utilized in forming the case  150 . In this embodiment, the comparatively higher density and impedance available from such a material structure may be taken advantage of to focus explosive energy into the forming jet during charge detonation as described further below. 
     Referring now to  FIG.  2 A , an enlarged view of the amorphous material liner  101  and surrounding architecture taken from  2 - 2  of  FIG.  1    are shown. The representative view of the amorphous liner  101  of  FIG.  2 A  is shown in contrast to the conventional prior art crystalline powder liner  200  and surrounding structure of  FIG.  2 B . For example, the prior art crystalline liner  200  of  FIG.  2 B  is of a repeating uniformity as a powder that is represented as a multitude of spheres in a pressed liner form. Thus, upon triggering of the underlying pellet  175 , the near immediate dispersal of powder from the pressed liner form may be understood. While adept at avoiding the formation of a slug and other large debris issues, the near immediate dispersal may adversely affect the ability of the emerging jet to display significant stretch. 
     With particular focus on  FIG.  2 A , the structure of the amorphous-based liner  101  may avoid the near immediate disintegration and dispersal of the prior art liner  200  of  FIG.  2 B . In this respect, the amorphous-based liner  101  may be more like a conventional solid liner. Yet, unlike a solid liner, the amorphous-based material is not a monolithic solid, but rather, is comprised of a suitable glass-like structure as depicted. Thus, with added reference to  FIG.  4 A , a notable stretch (S) may be achieved in jet formation, while at the same time, the liner material remains prone to substantial breakup. As a result, the formation of larger slug and debris pieces may be avoided so as to prevent blocking of perforations  425  created by the triggering of the pellet  175 . 
     Continuing with reference to  FIG.  2 A , with added reference to  FIG.  4 A , the amorphous-based liner  101  may utilize traditional liner materials such as tungsten, copper, lead, other metals, oxides and mixtures thereof, but in a glass form as opposed to a solid or powder form. Additionally, additives and fillers may be incorporated into the amorphous-based material. For example, binders or higher density additives, perhaps in crystalline powder form, may be incorporated to help tailor or further extend the stretch (S) of the jet  400  for sake of achieving a deeper perforation  425 . Indeed, a liner  101  of suitably high density amorphous material such as a tungsten glass may be of a less variable porosity and density as compared to a conventional crystalline powder liner (e.g.  200  of  FIG.  2 B ). Thus, a more continuous, cohesively stretching jet  400  may be realized for sake of the indicated deeper perforation  425  in absence of any notable formation of blocking debris. 
     The amorphous-based material liner  101  of  FIG.  2 A  may be formed in a variety of manners. For example, glass particles, including any additives or fillers, may be pressed like a more conventional powder liner. Similarly, such a matrix in the form of a glass bar may be machined into a liner akin to machining of a conventional solid metal liner. However, the amorphous-based material also lends itself to casting, injection molding and other manufacturing techniques. Indeed, as described further below, the liner  101  may even be three dimensionally printed. 
     Referring now to  FIG.  3   , an overview of an oilfield  300  is shown with a well  380  having a gun  305  located therein. The gun  305  is a perforating gun that is loaded with shaped charges  100  such as the one depicted in  FIG.  1   . Specifically, the gun  305  is outfitted with ports  301  that are aligned with shaped charges that have been loaded into the gun  305 . Thus, perforating of the adjacent casing  385  and formation  395  may take place. 
     The gun  305  of  FIG.  3    may be manufactured through conventional machining with thread and seal bores at either end. A separate laser cut steel tube may directly accommodate the shaped charges with the tube loaded into the gun  305  as a manner by which all of the charges may be simultaneously loaded. 
     Continuing with reference to  FIG.  3   , the gun  305  is deployed into the well  380  via wireline  310  and traversing various formation layers  390 ,  395  before reaching the target location shown. In the depicted embodiment, the gun  305  is deployed by the wireline  310  that is unwound from a reel  340  at a wireline truck  375 . Thus, a rig  350  may support lowering of the gun  305  past a wellhead  360  and into the well  380  for the noted perforating application. A control unit  377  located at the truck  375  may be utilized for directing the gun  305  to the target location in this manner. Once the perforating application is complete, the wireline  310 , gun  305  and any other associated tools may be removed from the well  380  to enhance flow from the formed perforations  425  and well  380  (see  FIG.  4 A ). Of course, a variety of other modes of delivery and retrieval may be utilized. 
     In order to keep the amount of debris formed during perforating at a minimum, the gun  305  may be constructed of an amorphous-based material with reactive agents incorporated therein. Thus, the gun  305  may be configured to disintegrate upon perforating with follow-on exothermal, oxidation or other tailored reaction taking place to break up the resultant debris into non-occlusive particle sizes. In fact, in one embodiment, such a disintegrating gun is formed via a three dimensional print application as described further below. 
     Referring now to  FIGS.  4 A- 4 C , with added reference to  FIG.  3   , side cross-sectional views of a shaped charge  100 , such as that of  FIG.  1   , are shown revealing jet formation upon firing. The charges  100  may have a case  150  of steel, zinc or even amorphous material with a liner most likely of amorphous material. Specifically,  FIG.  4 A  depicts the shaped charge  100  of  FIG.  1    utilizing an amorphous material liner  101  to form a deep penetrating jet  400  directed at the wall of the well  380 . Alternatively, the charge  100  may utilize a liner  410  of a larger profile to form a wide jet  401  as shown in  FIG.  4 B . Indeed, the liner  415 , jet  405  and resultant perforation  475  may all be of a tailored morphology as shown in  FIG.  4 C . 
     Regardless, the performance of each jet  400 ,  401 ,  405  may be enhanced by the inclusion of amorphous material within the shaped charge  100 , particularly the liner  101 ,  410 ,  415 , as described above. Thus, a slug-free terminal end  427 ,  457 ,  477  of a perforation  425 ,  450 ,  475  may be formed with sufficient penetration through casing  385 , underlying cement  490  and into the formation  395  adjacent the well  380 . In one embodiment, the liner  101 ,  410  and/or  415  may include reactive materials such as titanium to promote a reaction. Thus, the environment of the well and/or perforations  425 ,  450 ,  475  may remain effectively debris-free. In fact, in one embodiment, the amorphous materials may include reactive agents to allow for a lower initiation pressure during follow-on fracturing applications. In such embodiments, the reactive material may remain protected by amorphous or other surrounding materials but become exposed for reactivity following detonation. Such reactivity may even be utilized to actively reduce or “clean-out” some level of debris within perforations  425 ,  450 ,  475 . 
     High density powders such as tungsten may also be incorporated into the liner  101 ,  410 ,  415  to enhance jet density. Additionally, the material of the case  150  may be tailored to match that of the liner  101 ,  410 ,  415 . 
     With specific reference to  FIG.  4 A , upon firing of the shaped charge  100 , the liner  101  exits the seal  155  and a jet  400  takes shape which is directed at the well wall. The amorphous material of the jet  400  is of a given stretch (S) as measured from head  405  to tail  403 . The stretch (S) of the jet  400  may be enhanced by the use of the amorphous material of the liner  101  to provide a deeper penetration to the perforation  425 . This enhanced stretch (S) may be commensurate with a significant velocity gradient from head  405  to tail  403 . For example, material at the head  405  of the jet  400  may travel at 5 to 10 times the rate of speed as compared to material at the tail  403 . More specifically, in one embodiment, material at the head  405  of the jet  400  may travel at over 7 km/sec. whereas material at the tail  403  travels at less than about 1 km/sec. 
     With specific reference to  FIG.  4 B , amorphous material of the liner  410  may also be utilized to form a wide jet  401 . The jet  401  may again be of notable stretch (S′) from head  415  to tail  413  with a commensurate velocity gradient as indicated above. Yet at the same time, the higher profile liner  410  of amorphous material may be utilized in a manner that allows for construction of a big hole charge for a wider perforation  450 . However, as noted above, in contrast to solid liner based charges, use of an amorphous material in construction of the liner  410  is less prone to leaving behind a slug at the terminal end  457  of the perforation  450  that might interfere with hydrocarbon uptake. 
     Referring now to  FIG.  4 C  a side cross-sectional view of another embodiment of a shaped charge is shown in which the liner  415  is of a uniquely tailored morphology. Thus, the resultant jet  405  and ultimately the corresponding perforation  475  may also be of a tailored morphology. Again, a substantial velocity gradient may be present between material at the head  419  and that at the tail  417  of the jet  405  along with a significant stretch (S″). Thus, sufficient penetration may be attained. Further, as detailed below, the component that is this particular liner  415  may benefit from manufacture by way of three dimensional printing. That is, due to small, tight specifications on component of such unique morphology may be more efficiently produced by way of printing techniques. Indeed, as detailed regarding  FIG.  5    below, all charge components or even an entire gun system may be constructed from such printing techniques. 
     Referring now to  FIG.  5   , a side cross-sectional view of the shaped charge of  FIG.  4 C  is shown as it is being formed. Specifically, a multi-material three dimensional print manufacturing application  500  is being utilized to form the charge. However, in other embodiments individual single material components  150 ,  175 ,  415  may be formed one by one. Regardless, as noted above, three dimensional printing may be particularly beneficial where tight specifications on small features are involved. For example, see the heel  501  of the tailored liner  415  that is being produced. However, as a matter of process efficiency and avoiding time consuming steps involving subsequent component assembly, the entire charge may be simultaneously manufactured via three dimensional print techniques as depicted in  FIG.  5   . 
     Continuing with reference to  FIG.  5   , additive manufacturing, or three dimensional printing as referenced above, involves sequential layering of materials to manufacture a product. In the case of a shaped charge as shown, a support  530  suspends a deposition tool  525  at an appropriate and ascendable height over the forming charge. A carrier  550  at a table  575  therebelow may be moved via a conveyance  580  so as to allow the charge to take shape layer by layer during the printing process. 
     In addition to rapidly providing a charge or complete gun system, such three dimensional printing may allow a degree of specialized precision to components such as the liner  415 , thereby optimizing performance. For example, in the case of the liner  415 , tailoring the material gradient is rendered practical in addition to the morphology. In one embodiment, the liner  415  is of greater density, lesser porosity, or other characteristic at one end (e.g. at the skirt). Similarly, reactive materials, wave shape features, or other performance features may be precisely located at desired portions of the liner  415  due to the accuracy of the print technology. 
     Similar benefit may also be provided to the case  150  and/or explosive pellet  175 . For example, the case  150  may be of a controlled porosity with post explosive debris characteristics in mind. The case  150  may even be of a multi-point initiation with tunnels at its base. By the same token, density, porosity and other characteristics of the pellet  175  may be precisely provided layer by layer such that the explosive output and resultant jet performance is maximized. This may even include providing selectively integrated non-explosive materials. 
     In one embodiment, the loading tube, gun and entire gun system may be three dimensionally printed as described above. Thus, specialized materials such as fast corrosives or cavities may be layered into these parts to reduce weight without substantial effect on performance. Indeed, the entire system may be constructed of materials such as reactives and fast corrosives that are configured to disintegrate or “disappear” upon detonation. Thus, little or no debris may be left downhole upon perforating. 
     Referring now to  FIG.  6   , a flow-chart is shown summarizing an embodiment of forming and utilizing shaped charges incorporating amorphous materials. As indicated above, a multi-material three dimensional print application may be used to form a shaped charge as noted at  610 . Indeed, an entire gun system may also be manufactured in this manner ( 620 ). This may include printing of the gun followed by loading with component assembled shaped charges as noted or the whole system, both gun and entire charges, may all be simultaneously printed as part of a single print application. Alternatively, as indicated at  630  and  640 , component assembled shaped charges may be separately printed or manufactured for loading into a separately provided gun. 
     As noted above, with completed shaped charges in hand, the gun may be loaded as indicated at  650  and lowered into the well for a perforating application (see  660 ). As detailed hereinabove, benefits of utilizing amorphous materials, particularly those of the liner may be realized. Specifically, as indicated at  670 , detonation of shaped charges may form perforations from a jet of characteristics enhanced by the utilization of a liner of tailored amorphous materials. In fact, as indicated at  680 , debris-reducing reactions relative the gun, shaped charge components or even perforation clean-out may follow the perforating as a manner of maximizing follow-on hydrocarbon recovery. 
     Embodiments described hereinabove include a shaped charge that may be tailored of amorphous materials to substantially avoid the formation of a liner material slug that may become wedged within a perforation tunnel during the perforating. Thus, the effectiveness of the perforation for hydrocarbon uptake is not substantially hindered by such an occlusive or blocking type of material. By the same token, embodiments of the shaped charge may also be tailored to ensure the formation of an effective jet upon firing of the shaped charge. 
     The preceding description has been presented with reference to presently preferred embodiments. Persons skilled in the art and technology to which these embodiments pertain will appreciate that alterations and changes in the described structures and methods of operation may be practiced without meaningfully departing from the principle, and scope of these embodiments. Furthermore, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.