WO2004001178A2 - Method and apparatus for downhole pipe or casing repair - Google Patents

Method and apparatus for downhole pipe or casing repair Download PDF

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Publication number
WO2004001178A2
WO2004001178A2 PCT/US2003/014993 US0314993W WO2004001178A2 WO 2004001178 A2 WO2004001178 A2 WO 2004001178A2 US 0314993 W US0314993 W US 0314993W WO 2004001178 A2 WO2004001178 A2 WO 2004001178A2
Authority
WO
WIPO (PCT)
Prior art keywords
pipe
interior
plating
casing
tubing
Prior art date
Application number
PCT/US2003/014993
Other languages
French (fr)
Other versions
WO2004001178A3 (en
Inventor
Wenlin Zhang
Joe Walter
Original Assignee
Services Petroliers Schlumberger
Schlumberger Holdings Limited
Schlumberger Canada Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Services Petroliers Schlumberger, Schlumberger Holdings Limited, Schlumberger Canada Limited filed Critical Services Petroliers Schlumberger
Priority to AU2003249634A priority Critical patent/AU2003249634A1/en
Priority to US10/518,883 priority patent/US20060163075A1/en
Publication of WO2004001178A2 publication Critical patent/WO2004001178A2/en
Publication of WO2004001178A3 publication Critical patent/WO2004001178A3/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/18—Pretreatment of the material to be coated
    • C23C18/1803—Pretreatment of the material to be coated of metallic material surfaces or of a non-specific material surfaces
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/1601—Process or apparatus
    • C23C18/1603—Process or apparatus coating on selected surface areas
    • C23C18/1614—Process or apparatus coating on selected surface areas plating on one side
    • C23C18/1616—Process or apparatus coating on selected surface areas plating on one side interior or inner surface
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/1601—Process or apparatus
    • C23C18/1619—Apparatus for electroless plating
    • C23C18/1632—Features specific for the apparatus, e.g. layout of cells and of its equipment, multiple cells
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/31—Coating with metals
    • C23C18/32—Coating with nickel, cobalt or mixtures thereof with phosphorus or boron
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D21/00—Processes for servicing or operating cells for electrolytic coating
    • C25D21/12—Process control or regulation
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/34—Pretreatment of metallic surfaces to be electroplated
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00—Electroplating characterised by the article coated
    • C25D7/04—Tubes; Rings; Hollow bodies
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
    • F16L55/10—Means for stopping flow from or in pipes or hoses
    • F16L55/12—Means for stopping flow from or in pipes or hoses by introducing into the pipe a member expandable in situ
    • F16L55/128—Means for stopping flow from or in pipes or hoses by introducing into the pipe a member expandable in situ introduced axially into the pipe or hose
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
    • F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
    • F16L58/04—Coatings characterised by the materials used
    • F16L58/10—Coatings characterised by the materials used by rubber or plastics
    • F16L58/1009—Coatings characterised by the materials used by rubber or plastics the coating being placed inside the pipe

Definitions

  • the subject matter of the present invention relates to a method and apparatus for downhole pipe or casing repair including a corrosion monitoring tool for evaluating the extent of corrosion on an internal surface of a pipe, a surface treatment apparatus, such as a sand blaster, for cleaning the internal surface of the pipe and removing the corrosion, and a plating apparatus for plating a new metallic layer on the internal surface of the pipe.
  • a corrosion monitoring tool for evaluating the extent of corrosion on an internal surface of a pipe
  • a surface treatment apparatus such as a sand blaster
  • a plating apparatus for plating a new metallic layer on the internal surface of the pipe.
  • Corrosion in an oil or gas well is a problem.
  • Tubing disposed downhole in a wellbore can become corroded with rust and, as a result, it is often necessary to determine the extent of that corrosion on an internal surface of the tubing disposed downhole.
  • Corrosion monitoring tools can determine the extent of that corrosion, however, when the corrosion monitoring tool is disposed downhole, there exists no additional apparatus disposed downhole with the corrosion monitoring tool for concurrently repairing the internal surface of the corroded tubing.
  • one aspect of the present invention includes a downhole pipe repair apparatus, comprising: a surface treatment apparatus adapted for cleaning an interior surface of the pipe; and a plating apparatus adapted for plating a new surface on the interior surface of the pipe after the surface treatment apparatus cleans the interior surface of the pipe.
  • Another aspect of the present invention includes a downhole pipe repair apparatus, comprising: a surface treatment apparatus adapted for cleaning an interior surface of the pipe; a plating apparatus adapted for plating a new surface on the interior surface of the pipe after the surface treatment apparatus cleans the interior surface of the pipe; and a corrosion monitoring tool adapted for examining the interior surface of the pipe after the plating apparatus plates the new surface on the interior surface of the pipe.
  • Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: cleaning an interior of the pipe, and plating a new surface on the interior of the pipe after the cleaning step.
  • Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: examining the interior of the pipe, cleaning the interior of the pipe after the examining step, and plating a new surface on the interior of the pipe after the cleaning step.
  • Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: examining the interior of the pipe, cleaning the interior of the pipe after the examining step, plating a new surface on the interior of the pipe after the cleaning step, and re-examining the interior of the pipe after the plating step.
  • figure 1 illustrates a preferred embodiment of the downhole pipe or casing repair apparatus of the present invention
  • figure 2 illustrates a more detailed construction of the downhole pipe or casing repair apparatus of figure 1 of the present invention
  • figure 3 illustrates a detailed construction of the surface treatment apparatus portion of the downhole pipe or casing repair apparatus of figure 2
  • figure 4 illustrates an alternate embodiment of the corrosion monitoring tool of figure 1, figure 2 illustrating one embodiment of the corrosion monitoring tool of figure 1, and figure 4 illustrating another embodiment of the corrosion monitoring tool of figure 1, and
  • FIGS 5 A and 5B illustrate the principle behind the operation of the alternate embodiment of the corrosion monitoring tool of figure 4.
  • a downhole pipe or casing repair apparatus 10 adapted to be disposed inside a tubing or pipe or casing 16 in a wellbore 12, is illustrated.
  • the downhole pipe or casing repair apparatus 10 includes a corrosion monitoring tool 14 adapted for examining the internal wall of the tubing 16 to determine the extent of any corrosion or rust which may exist on the inside of the tubing 16, a surface treatment apparatus 18 adapted for cleaning the inside of the tubing 16 when corrosion or rust is determined to exist on the inside of the tubing 16, a plating apparatus 20 adapted for plating a new metallic layer on the inside of the tubing 16 when the surface treatment apparatus 18 cleans the inside of the tubing 16, a packer sealing apparatus 22 adapted for sealing off the surface treatment apparatus 18 from the corrosion monitoring tool 14 when the surface treatment apparatus 18 is cleaning the inside of the tubing 16, and a packer sealing apparatus 23 adapted for sealing off the plating apparatus 20 from the surface treatment apparatus 18 when the plating apparatus 20 is plating the new metallic layer on the inside of the tubing 16.
  • the downhole pipe or casing repair apparatus 10 includes the corrosion monitoring tool 14 which is owned and operated by Schlumberger Technology Corporation of Houston, Texas.
  • corrosion monitoring tools 14 which are owned and operated by Schlumberger Technology Corporation, include the CPET tool, the METT tool, and the CET tool.
  • monitoring tool 14 includes a plurality of fingers 14a extending from a central conductor 14b, the fingers 14a being adapted for contacting the inside 16a of the tubing 16 and flexing when the corrosion monitoring tool 14 is pushed downwardly or pulled upwardly inside the tubing 16.
  • an electrical signal is generated in each finger 14a which is proportional to and representative of the extent of the corrosion which exists on the inside 16a of the pipe or tubing or casing 16.
  • the electrical signal from each finger 14a propagates uphole and is recorded on a log which displays the extent of the corrosion existing on the inside 16a of the tubing 16.
  • the downhole pipe or casing repair apparatus 10 further includes a surface treatment apparatus 18 which further includes a cleaning apparatus 18a adapted for cleaning the inside 16a of the pipe or tubing or casing 16 and a container 18b adapted for collecting any corrosive elements which are removed from the inside 16a of the pipe or tubing or casing 16 when the cleaning apparatus 18a cleans the inside 16a of the tubing or casing 16.
  • a packer sealing apparatus 22 is disposed between the corrosion monitoring tool 14 and the surface treatment apparatus 18, the packer sealing apparatus 22 sealing off the surface treatment apparatus 18 from the corrosion monitoring tool 14 inside the pipe or tubing or casing 16 when the surface treatment apparatus 18 is cleaning the inside 16a of the pipe or tubing or casing 16.
  • the downhole pipe or casing repair apparatus 10 further includes a plating apparatus 20, the plating apparatus 20 further including an anode 20a, a cathode 20b which is the pipe or tubing or casing 16, and an electrolyte 20c disposed between the anode 20a and the cathode 20b.
  • the plating apparatus 20 further including an anode 20a, a cathode 20b which is the pipe or tubing or casing 16, and an electrolyte 20c disposed between the anode 20a and the cathode 20b.
  • a spacer/centralizer 20d will centralize the anode 20a inside the pipe or tubing or casing 16.
  • the anode 20a is adapted for depositing a metallic layer on the cathode 20b via an electrolytic reaction when a voltage "V" is applied across the anode 20a and cathode 20b.
  • a packer sealing apparatus 23 is disposed between the plating apparatus 20 and the surface treatment apparatus 18, the packer sealing apparatus 23 sealing off the plating apparatus 20 from
  • the cleaning apparatus 18a of figure 2 includes a central bore 18al in which a fluid or sand propagates downwardly in figure 3 along a longitudinal axis of the cleaning apparatus 18a, and a transverse bore 18a2 in which the fluid or sand will propagate from the central bore 18al in a transverse direction with respect to the longitudinal axis of the cleaning apparatus, as shown in figure 3.
  • the cleaning apparatus 18a of figure 3 can be the "Jet Blaster" tool that is owned and operated by Schlumberger Technology Corporation of Houston, Texas.
  • the Jet Blaster cleaning apparatus 18a of figure 3 will propagate a fluid or sand at a high velocity through the central bore 18al and through the transverse bore 18a2, the fluid or sand being blasted against the inside 16a of the pipe or tubing or casing 16 at the high velocity thereby removing the corroded areas 24 from the inside 16a of the pipe or tubing or casing 16.
  • the corrosive elements of the corroded areas 24 will fall into the container 18b when the corrosive elements are removed from the inside 16a of the pipe or tubing or casing 16 by the Jet Blaster cleaning apparatus 18a of figure 3.
  • FIG 4 an alternate embodiment of the corrosion monitoring tool 14 of figure 1 is illustrated.
  • the alternate embodiment of the corrosion monitoring tool 14 of figure 1 is an Ultrasonic Imaging Tool that uses a single rotating transducer 26, housed in a sub at the bottom of the tool, to give full coverage of the tubing or casing 16.
  • the transducer 26 is used to resonate the tubing or casing 16.
  • the fundamental mode of resonance is analyzed in the received waveform to obtain information regarding the existence of corrosion on the inside 16a of the pipe or tubing or casing 16.
  • the Ultra Sonic Imaging Tool of figure 4 is owned and operated by Schlumberger Technology Corporation of Houston, Texas. The principle of operation of
  • a sonic monopole transmitter 28 produces positive compressional waves in the tubing or casing 16 on both sides of the transmitter via volumetric expansion and constraction of the transmitter 28. Compressional waves are generated in the pipe or tubing or casing 16, the compressional waves propagating longitudinally along the axis of the pipe or tubing or casing 16. One or more corroded areas 24 on the inside of the pipe or tubing or casing 16 will affect the propagation of the compressional waves which are propagating along the pipe or tubing or casing 16.
  • a receiver 30 will record the compressional waves which are received from the pipe or tubing or casing 16, that record produced by the receiver 30 reflecting the extent of the corroded areas 24 which exist on the inside of the pipe or tubing, or casing 16.
  • a sonic dipole transmitter 32 produces a positive shear wave on one side of the pipe or tubing or casing 16 and a negative shear wave on the other side of the pipe or tubing or casing 16. No net volume change is produced.
  • a positive shear wave propagates longitudinally on one side of the pipe or tubing or casing 16 and a negative shear wave propagates longitudinally on the other side of the pipe or tubing or casing 16.
  • One or more corroded areas 24 on the inside of the pipe or tubing or casing 16 will affect the propagation of the shear waves which are propagating along the pipe or tubing or casing 16.
  • a receiver 34 will record the shear waves which are received from the pipe or tubing or casing 16, that record produced by the receiver 34 reflecting the extent of the corroded areas 24 which exist on the inside of the pipe or tubing or casing 16.
  • the packer sealing apparatus 22 will seal off the corrosion monitoring tool 14 of figure 1 from the surface treatment apparatus 18 and the packer sealing apparatus 23 will seal off the surface treatment apparatus 18 from the plating apparatus 20, since an electrolyte solution 20c will be disposed above the packer sealing apparatus 23 inside the pipe or tubing or casing 16 of figure 2.
  • the cleaning apparatus 18a cleans the inside 16a of the pipe or tubing or casing 16 by initially rapidly propagating a fluid or sand down the central bore 18al of the cleaning apparatus 18a, in figure 3, at a high velocity and then rapidly propagating the fluid or sand transversely through the transverse bore 18a2 of the cleaning apparatus 18a at a high velocity, the rapidly propagating fluid or sand which is transversely propagating in the transverse bore 18a2 striking the inside 16a of the pipe or tubing or casing 16 while the downhole pipe or casing repair apparatus 10 is still moving downwardly inside the pipe or tubing or casing 16.
  • the rapidly propagating fluid or sand, exiting the transverse bore 18a2 of figure 3 will function as a jet blaster since the fluid or sand will
  • the inside 16a of the tubing or casing 16 can be acid washed using an acid solution comprised of approximately 15% of HCL in order to remove any rust from the inside 16a of the tubing or casing 16 prior to a plating operation using the plating apparatus 20 of figures 1 and 2.
  • the new metallic layer can be either Chromium, Iron, Nickel, or Copper.
  • Electroless or chemical plating is a chemical deposition process autocatalytically occurring on the metal surface without applying electric current in contrast to the conventional electroplating.
  • the deposited metal ions are reduced on the metal surface by reducing agents instead of current.
  • the reducing agents give up electrons to the deposited ions directly forming a metal layer which is coated on the substrate surface. Due to the chemical reaction, the thickness of the coated metal layer is very uniform and accurate as compared with electroplating, especially in connection with a complicated shape of metal parts.
  • Electroless Ni and its alloy (Ni-P) were proven superior in corrosion resistance, especially in a highly corrosive oil and gas production environment, which may contain H2S, CO2 and brine at high pressure and high temperature.
  • the corrosion monitoring tool 14 shown in figure 2 could be used in order to accomplish the function of the downhole pipe or casing repair apparatus 10 of the present invention.

Abstract

A downhole pipe or casing repair method and apparatus (10) includes a corrosion monitoring tool adapted for examining an interior of a pipe or tubing or casing (16) to create a record of the condition of said interior of said pipe, a surface treatment apparatus for cleaning said interior of said pipe, a plating apparatus for plating a new surface over the interior of said pipe after the surface treatment apparatus cleans the interior of said pipe, a packer sealing apparatus for sealing the surface treatment apparatus from the corrosion monitoring tool (14), and another packer sealing apparatus for sealing the plating apparatus from the surface treatment apparatus (18). The corrosion monitoring tool will examine the interior of the pipe, the surface treatment apparatus will clean the interior of the pipe, the plating apparatus (20) will plate a new surface over the newly cleaned interior of the pipe, and the corrosion monitoring tool will re-examine the interior of the pipe after the plating step is completed.

Description

METHOD AND APPARATUS FOR DOWNHOLE PIPE OR CASING REPAIR
BACKGROUND OF THE INVENTION
The subject matter of the present invention relates to a method and apparatus for downhole pipe or casing repair including a corrosion monitoring tool for evaluating the extent of corrosion on an internal surface of a pipe, a surface treatment apparatus, such as a sand blaster, for cleaning the internal surface of the pipe and removing the corrosion, and a plating apparatus for plating a new metallic layer on the internal surface of the pipe.
Corrosion in an oil or gas well is a problem. Tubing disposed downhole in a wellbore can become corroded with rust and, as a result, it is often necessary to determine the extent of that corrosion on an internal surface of the tubing disposed downhole. Corrosion monitoring tools can determine the extent of that corrosion, however, when the corrosion monitoring tool is disposed downhole, there exists no additional apparatus disposed downhole with the corrosion monitoring tool for concurrently repairing the internal surface of the corroded tubing. Therefore, although it would be desirable to determine the extent of the corrosion on the internal surface of the pipe, there exists no additional apparatus for concurrently repairing the corroded pipe downhole without pulling the pipe out of the wellbore, replacing the pipe, and increasing the rig-time and the resultant costs to a customer.
Therefore, a need exists to provide a downhole pipe or casing repair apparatus adapted to be disposed in a wellbore which would include a surface treatment apparatus and a plating apparatus in addition to the corrosion monitoring tool, the downhole pipe or casing repair apparatus using the corrosion monitoring tool to monitor the extent of the corrosion on an internal surface of a pipe disposed downhole and, when the corrosion is
68.0327 1 detected, repairing the internal surface of the pipe by using the surface treatment apparatus to remove the corrosion from the internal surface of the pipe and using the plating apparatus to plate a new metallic layer on the internal surface of the pipe disposed downhole.
SUMMARY OF THE INVENTION
Accordingly, one aspect of the present invention includes a downhole pipe repair apparatus, comprising: a surface treatment apparatus adapted for cleaning an interior surface of the pipe; and a plating apparatus adapted for plating a new surface on the interior surface of the pipe after the surface treatment apparatus cleans the interior surface of the pipe.
Another aspect of the present invention includes a downhole pipe repair apparatus, comprising: a surface treatment apparatus adapted for cleaning an interior surface of the pipe; a plating apparatus adapted for plating a new surface on the interior surface of the pipe after the surface treatment apparatus cleans the interior surface of the pipe; and a corrosion monitoring tool adapted for examining the interior surface of the pipe after the plating apparatus plates the new surface on the interior surface of the pipe.
Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: cleaning an interior of the pipe, and plating a new surface on the interior of the pipe after the cleaning step.
Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: examining the interior of the pipe, cleaning the interior of the pipe after the examining step, and plating a new surface on the interior of the pipe after the cleaning step.
68.0327 Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: examining the interior of the pipe, cleaning the interior of the pipe after the examining step, plating a new surface on the interior of the pipe after the cleaning step, and re-examining the interior of the pipe after the plating step.
Further scope of applicability of the present invention will become apparent from the detailed description presented hereinafter. It should be understood, however, that the detailed description and the specific examples, while representing a preferred embodiment of the present invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become obvious to one skilled in the art from a reading of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the present invention will be obtained from the detailed description of the preferred embodiment presented hereinbelow, and the accompanying drawings, which are given by way of illustration only and are not intended to be limitative of the present invention, and wherein:
figure 1 illustrates a preferred embodiment of the downhole pipe or casing repair apparatus of the present invention;
figure 2 illustrates a more detailed construction of the downhole pipe or casing repair apparatus of figure 1 of the present invention;
figure 3 illustrates a detailed construction of the surface treatment apparatus portion of the downhole pipe or casing repair apparatus of figure 2,
68.0327 figure 4 illustrates an alternate embodiment of the corrosion monitoring tool of figure 1, figure 2 illustrating one embodiment of the corrosion monitoring tool of figure 1, and figure 4 illustrating another embodiment of the corrosion monitoring tool of figure 1, and
figures 5 A and 5B illustrate the principle behind the operation of the alternate embodiment of the corrosion monitoring tool of figure 4.
DESCRIPTION OF THE INVENTION
Referring to figure 1, a downhole pipe or casing repair apparatus 10, adapted to be disposed inside a tubing or pipe or casing 16 in a wellbore 12, is illustrated. In figure 1, the downhole pipe or casing repair apparatus 10 includes a corrosion monitoring tool 14 adapted for examining the internal wall of the tubing 16 to determine the extent of any corrosion or rust which may exist on the inside of the tubing 16, a surface treatment apparatus 18 adapted for cleaning the inside of the tubing 16 when corrosion or rust is determined to exist on the inside of the tubing 16, a plating apparatus 20 adapted for plating a new metallic layer on the inside of the tubing 16 when the surface treatment apparatus 18 cleans the inside of the tubing 16, a packer sealing apparatus 22 adapted for sealing off the surface treatment apparatus 18 from the corrosion monitoring tool 14 when the surface treatment apparatus 18 is cleaning the inside of the tubing 16, and a packer sealing apparatus 23 adapted for sealing off the plating apparatus 20 from the surface treatment apparatus 18 when the plating apparatus 20 is plating the new metallic layer on the inside of the tubing 16.
Referring to figure 2, a detailed construction of the downhole pipe or casing repair apparatus 10 of figure 1 is illustrated. In figure 2, the downhole pipe or casing repair apparatus 10 includes the corrosion monitoring tool 14 which is owned and operated by Schlumberger Technology Corporation of Houston, Texas. Examples of such corrosion monitoring tools 14, which are owned and operated by Schlumberger Technology Corporation, include the CPET tool, the METT tool, and the CET tool. The corrosion
68.0327 monitoring tool 14 includes a plurality of fingers 14a extending from a central conductor 14b, the fingers 14a being adapted for contacting the inside 16a of the tubing 16 and flexing when the corrosion monitoring tool 14 is pushed downwardly or pulled upwardly inside the tubing 16. During the flexing of the fingers 14a, an electrical signal is generated in each finger 14a which is proportional to and representative of the extent of the corrosion which exists on the inside 16a of the pipe or tubing or casing 16. The electrical signal from each finger 14a propagates uphole and is recorded on a log which displays the extent of the corrosion existing on the inside 16a of the tubing 16. The downhole pipe or casing repair apparatus 10 further includes a surface treatment apparatus 18 which further includes a cleaning apparatus 18a adapted for cleaning the inside 16a of the pipe or tubing or casing 16 and a container 18b adapted for collecting any corrosive elements which are removed from the inside 16a of the pipe or tubing or casing 16 when the cleaning apparatus 18a cleans the inside 16a of the tubing or casing 16. A packer sealing apparatus 22 is disposed between the corrosion monitoring tool 14 and the surface treatment apparatus 18, the packer sealing apparatus 22 sealing off the surface treatment apparatus 18 from the corrosion monitoring tool 14 inside the pipe or tubing or casing 16 when the surface treatment apparatus 18 is cleaning the inside 16a of the pipe or tubing or casing 16. The downhole pipe or casing repair apparatus 10 further includes a plating apparatus 20, the plating apparatus 20 further including an anode 20a, a cathode 20b which is the pipe or tubing or casing 16, and an electrolyte 20c disposed between the anode 20a and the cathode 20b. Note the corroded areas 24 which exist on the inside 16a of the pipe or tubing or casing 16. A spacer/centralizer 20d will centralize the anode 20a inside the pipe or tubing or casing 16. The anode 20a is adapted for depositing a metallic layer on the cathode 20b via an electrolytic reaction when a voltage "V" is applied across the anode 20a and cathode 20b. Assume that the plus side of voltage V is applied to the anode 20a via a central conductor 21 and the negative side of the voltage V is applied to the tubing or casing 'cathode' 20b. The metallic layer can be either a Nickel (Ni), Chromium (Cr), Iron (Fe), or Copper (Cu) layer. A packer sealing apparatus 23 is disposed between the plating apparatus 20 and the surface treatment apparatus 18, the packer sealing apparatus 23 sealing off the plating apparatus 20 from
68.0327 the surface treatment apparatus 18 inside the pipe or tubing or casing 16 when the plating apparatus 20 is plating a new metallic layer on the inside 16a of the pipe or tubing or casing 16.
Referring to figure 3, a detailed construction of the cleaning apparatus 18a of figure 2 is illustrated. In figure 3, although the cleaning apparatus 18a can be either a mechanical cleaning apparatus or an ultrasonic cleaning apparatus, the cleaning apparatus 18a of figure 3 includes a central bore 18al in which a fluid or sand propagates downwardly in figure 3 along a longitudinal axis of the cleaning apparatus 18a, and a transverse bore 18a2 in which the fluid or sand will propagate from the central bore 18al in a transverse direction with respect to the longitudinal axis of the cleaning apparatus, as shown in figure 3. The cleaning apparatus 18a of figure 3 can be the "Jet Blaster" tool that is owned and operated by Schlumberger Technology Corporation of Houston, Texas. In operation, the Jet Blaster cleaning apparatus 18a of figure 3 will propagate a fluid or sand at a high velocity through the central bore 18al and through the transverse bore 18a2, the fluid or sand being blasted against the inside 16a of the pipe or tubing or casing 16 at the high velocity thereby removing the corroded areas 24 from the inside 16a of the pipe or tubing or casing 16. The corrosive elements of the corroded areas 24 will fall into the container 18b when the corrosive elements are removed from the inside 16a of the pipe or tubing or casing 16 by the Jet Blaster cleaning apparatus 18a of figure 3.
Referring to figures 4, 5 A and 5B, an alternate embodiment of the corrosion monitoring tool 14 of figure 1 is illustrated. In figure 4, the alternate embodiment of the corrosion monitoring tool 14 of figure 1 is an Ultrasonic Imaging Tool that uses a single rotating transducer 26, housed in a sub at the bottom of the tool, to give full coverage of the tubing or casing 16. In figure 4, the transducer 26 is used to resonate the tubing or casing 16. The fundamental mode of resonance is analyzed in the received waveform to obtain information regarding the existence of corrosion on the inside 16a of the pipe or tubing or casing 16. The Ultra Sonic Imaging Tool of figure 4 is owned and operated by Schlumberger Technology Corporation of Houston, Texas. The principle of operation of
68.0327 the Ultrasonic Imaging Tool of figure 4 is discussed below with reference to figures 5 A and 5B. In figure 5 A, a sonic monopole transmitter 28 produces positive compressional waves in the tubing or casing 16 on both sides of the transmitter via volumetric expansion and constraction of the transmitter 28. Compressional waves are generated in the pipe or tubing or casing 16, the compressional waves propagating longitudinally along the axis of the pipe or tubing or casing 16. One or more corroded areas 24 on the inside of the pipe or tubing or casing 16 will affect the propagation of the compressional waves which are propagating along the pipe or tubing or casing 16. A receiver 30 will record the compressional waves which are received from the pipe or tubing or casing 16, that record produced by the receiver 30 reflecting the extent of the corroded areas 24 which exist on the inside of the pipe or tubing, or casing 16. In figure 5B, a sonic dipole transmitter 32 produces a positive shear wave on one side of the pipe or tubing or casing 16 and a negative shear wave on the other side of the pipe or tubing or casing 16. No net volume change is produced. A positive shear wave propagates longitudinally on one side of the pipe or tubing or casing 16 and a negative shear wave propagates longitudinally on the other side of the pipe or tubing or casing 16. One or more corroded areas 24 on the inside of the pipe or tubing or casing 16 will affect the propagation of the shear waves which are propagating along the pipe or tubing or casing 16. A receiver 34 will record the shear waves which are received from the pipe or tubing or casing 16, that record produced by the receiver 34 reflecting the extent of the corroded areas 24 which exist on the inside of the pipe or tubing or casing 16. The principle of operation described above with reference to figures 5A and 5B is also discussed in U.S. Patent 5,036,945 to Hoyle et al, the disclosure of which is incorporated by reference into this specification.
A functional description of the operation of the downhole pipe or casing repair apparatus 10 of the present invention will be set forth in the following paragraphs with reference to figures 1 through 5B of the drawings.
Assume that the downhole pipe or casing repair apparatus 10 of figures 1 and 2, which includes the corrosion monitoring tool 14, the packer sealing apparatus 22, the surface
68.0327 treatment apparatus 18, the packer sealing apparatus 23, and the plating apparatus 20, is lowered downwardly into the pipe or tubing or casing 16, as indicated by downwardly directed arrow 17 in figure 2. In figure 2, in response to the downward movement of the downhole pipe or casing repair apparatus 10, the fingers 14a of the corrosion monitoring tool 14 will flex whenever corroded areas 24 are encountered on the inside 16a of the tubing 16 thereby generating an electrical signal which propagates uphole along the central conductor 21 and records the existence of corroded areas 24 on the inside 16a of the pipe or tubing or casing 16. The packer sealing apparatus 22 will seal off the corrosion monitoring tool 14 of figure 1 from the surface treatment apparatus 18 and the packer sealing apparatus 23 will seal off the surface treatment apparatus 18 from the plating apparatus 20, since an electrolyte solution 20c will be disposed above the packer sealing apparatus 23 inside the pipe or tubing or casing 16 of figure 2. In figure 2, in response to the downward movement of the downhole pipe or casing repair apparatus 10, when the corrosion monitoring tool 14 is recording the existence of the corroded areas 24 on the inside of the pipe or tubing or casing 16, and when the packer sealing apparatus 22 and 23 are both firmly sealed against the inside 16a of the tubing or casing 16, the cleaning apparatus 18a of the surface treatment apparatus 18 is busy cleaning the inside 16a of the pipe or tubing or casing 16 by removing the corroded areas 24 from the inside 16a of the pipe or tubing or casing 16. When the corroded areas 24 are removed from the inside 16a of the tubing or casing 16 by the cleaning apparatus 18 a, the removed corroded areas 24 are deposited into the container 18b of the surface treatment apparatus 18. In figure 3, the cleaning apparatus 18a cleans the inside 16a of the pipe or tubing or casing 16 by initially rapidly propagating a fluid or sand down the central bore 18al of the cleaning apparatus 18a, in figure 3, at a high velocity and then rapidly propagating the fluid or sand transversely through the transverse bore 18a2 of the cleaning apparatus 18a at a high velocity, the rapidly propagating fluid or sand which is transversely propagating in the transverse bore 18a2 striking the inside 16a of the pipe or tubing or casing 16 while the downhole pipe or casing repair apparatus 10 is still moving downwardly inside the pipe or tubing or casing 16. As a result, the rapidly propagating fluid or sand, exiting the transverse bore 18a2 of figure 3, will function as a jet blaster since the fluid or sand will
68.0327 blast against the inside 16a of the pipe or tubing or casing 16 while the downhole pipe or casing repair apparatus 10 is moving downwardly inside the pipe or tubing or casing 16 of figures 1 or 2. The corroded areas 24 are removed from the inside 16a of the pipe or tubing or casing 16, the removed corroded areas 24 being deposited into the container 18b of the surface treatment apparatus 18. In addition to or simultaneously with the blasting of the fluid or sand from the transverse bore 18a2 of the cleaning apparatus 18a of figure 3 against the inside of the tubing or casing 16, the inside 16a of the tubing or casing 16 can be acid washed using an acid solution comprised of approximately 15% of HCL in order to remove any rust from the inside 16a of the tubing or casing 16 prior to a plating operation using the plating apparatus 20 of figures 1 and 2. In figure 2, in response to the downward movement of the downhole pipe or casing repair apparatus 10, when the corrosion monitoring tool 14 is recording the existence of the corroded areas 24 on the inside of the tubing or casing 16, and when the packer sealing apparatus 22 and 23 are both firmly sealed against the inside 16a of the tubing or casing 16, and when the cleaning apparatus 18a of the surface treatment apparatus 18 is cleaning the inside 16a of the pipe or tubing or casing 16, the plating apparatus 20 is busy plating a new metallic surface on the inside.16a of the tubing or casing 16. In figure 2, a voltage V is applied across the anode 20a and the cathode 20b when an electrolyte solution 20c is disposed inside the pipe or tubing or casing 16 above the packer sealing apparatus 23. As a result, due to an electrolytic reaction which is taking place between the anode 20a and the cathode 20b in figure 2, a new metallic layer is being deposited on the inside 16a of the tubing or casing 16 of figure 2, the new metallic layer being deposited over the cleaned areas on the inside 16a of the tubing or casing 16 where the corroded areas 24 previously existed. The new metallic layer can be either Chromium, Iron, Nickel, or Copper.
In figure 2, the downhole pipe or casing repair apparatus 10 of figure 2 is now moved upwardly inside the pipe or tubing or casing 16 for the purpose of confirming the repaired pipe or tubing or casing, as indicated by the upwardly directed arrow 19 in figure 2. During the movement upwardly inside the pipe or tubing or casing 16, the corrosion monitoring tool 14 of figures 1 and 2 will now create a new record of the existence of any
68.0327 remaining corroded areas 24, if any, on the inside 16a of the tubing or casing 16. The fingers 14a of the corrosion monitoring tool 14 of figure 2 will flex when a corroded area 24 is encountered on the inside 16a of the pipe or tubing or casing 16. However, in view of the above referenced cleaning operation, wherein the inside 16a of the pipe or tubing or casing 16 was cleaned by the surface treatment apparatus 18 and the inside 16a was plated by the plating apparatus 20, the new record of the inside 16a of the pipe or tubing or casing 16 that was created by the corrosion monitoring tool 14 will now record the absence of any corroded areas 24 on the inside 16a of the pipe or tubing or casing 16.
Instead of using the electrolytic plating apparatus 20 shown in figure 2, a chemical plating method and apparatus could be used. Electroless or chemical plating is a chemical deposition process autocatalytically occurring on the metal surface without applying electric current in contrast to the conventional electroplating. The deposited metal ions are reduced on the metal surface by reducing agents instead of current. The reducing agents give up electrons to the deposited ions directly forming a metal layer which is coated on the substrate surface. Due to the chemical reaction, the thickness of the coated metal layer is very uniform and accurate as compared with electroplating, especially in connection with a complicated shape of metal parts. Electroless Ni and its alloy (Ni-P) were proven superior in corrosion resistance, especially in a highly corrosive oil and gas production environment, which may contain H2S, CO2 and brine at high pressure and high temperature.
In addition, instead of using the corrosion monitoring tool 14 shown in figure 2, the corrosion monitoring tool shown in figures 4 and 5 could be used in order to accomplish the function of the downhole pipe or casing repair apparatus 10 of the present invention.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
68.0327 10

Claims

WE CLAIM:
1. A downhole pipe repair apparatus, comprising:
a surface treatment apparatus adapted for cleaning an interior surface of said pipe; and a plating apparatus adapted for plating a new surface on the interior surface of said pipe after said surface treatment apparatus cleans said interior surface of said pipe.
2. The downhole pipe repair apparatus of claim 1 , further comprising:
a corrosion monitoring tool adapted for examining said interior surface of said pipe after said plating apparatus plates said new surface on said interior surface of said pipe.
3. The downhole pipe repair apparatus of claim 2, further comprising:
a sealing apparatus disposed between the corrosion monitoring tool and said surface treatment apparatus adapted for sealing off. said surface treatment apparatus from said corrosion monitoring tool inside said pipe.
4. The downhole pipe repair apparatus of claim 3, further comprising:
A sealing apparatus disposed between the surface treatment apparatus and the plating apparatus adapted for sealing off said plating apparatus from said surface treatment apparatus inside said pipe.
68.0327 11 ■
5. A method for downhole pipe repair, said method comprising:
cleaning an interior of said pipe; and plating a new surface on the interior of said pipe after the cleaning step.
6. The method of claim 5, wherein the cleaning step further comprises:
examining said interior of said pipe; and cleaning said interior of said pipe after the examining step.
7. The method of claim 6, wherein the plating step comprises an electrolytic plating step.
8. The method of claim 6, wherein the plating step comprises a chemical plating step.
9. The method of claim 6, wherein the cleaning step comprises blasting a material against said interior of said pipe thereby generating removed corroded areas, and collecting removed corroded areas in a container.
10. The method of claim 6, said method further comprising re-examining said interior of said pipe after the plating step.
11. The method of claim 10, wherein the examining and the re-examining step each further comprise:
68.0327 12. pressing one or more fingers against said interior of said pipe, passing said fingers over said interior of said pipe, and flexing said fingers when a corroded area is encountered on said interior; and generating an electrical signal in response to the flexing step representative of said corroded area..
12. The method of claim 10, wherein the examining and the re-examining step each further comprise:
propagating a compressional or shear wave through one or more corroded areas on said interior of said pipe, receiving the compressional or shear waves from the interior of said pipe, and generating a record of the received compressional or . shear waves representative of said corroded areas.
68.0327 13
PCT/US2003/014993 2002-06-21 2003-05-14 Method and apparatus for downhole pipe or casing repair WO2004001178A2 (en)

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US8101050B2 (en) 2006-06-20 2012-01-24 Vetco Gray Inc. System, method, and apparatus for continuous electroplating of elongated workpieces

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US3857772A (en) * 1971-12-25 1974-12-31 Toyo Kogyo Co Electroplating apparatus for simultaneously and uniformly electroplating inside surfaces of annular bodies
US4826582A (en) * 1985-08-05 1989-05-02 Framatome Surface treatment process and device for heat exchangers
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Publication number Priority date Publication date Assignee Title
GB2439807A (en) * 2006-06-20 2008-01-09 Vetco Gray Inc A localised electroplating system
GB2476405A (en) * 2006-06-20 2011-06-22 Vetco Gray Inc System, method and apparatus for continuous electroplating of elongated work pieces
GB2439807B (en) * 2006-06-20 2012-01-04 Vetco Gray Inc Apparatus for continuous electroplating of elongated workpieces
GB2476405B (en) * 2006-06-20 2012-01-11 Vetco Gray Inc Apparatus for continuous electroplating of elongated workpieces
US8101050B2 (en) 2006-06-20 2012-01-24 Vetco Gray Inc. System, method, and apparatus for continuous electroplating of elongated workpieces

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AU2003249634A8 (en) 2004-01-06
WO2004001178A3 (en) 2004-04-08
US20060163075A1 (en) 2006-07-27
AU2003249634A1 (en) 2004-01-06

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