Downhole oilfield apparatus comprising a diamond-like carbon coating and methods of use

Abstract

Downhole apparatus and methods of using the apparatus are described, the apparatus comprising at least one metallic component having a DLC coating thereon, the coating present at least on one or more internal passageways of the base metal or alloy to be exposed to downhole environments. Methods of using an apparatus in downhole oilfield operations are also described. This abstract allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It will not be used to interpret or limit the scope or meaning of the claims.

1 . A downhole oilfield apparatus of base metal or alloy having a coating thereon comprising diamond-like carbon (DLC), the coating present at least on one or more internal passageways of the base metal or alloy to be exposed to downhole environments such as completion and produced fluids, the apparatus selected from downhole tools having one or more of the following functions: control, change, isolate, restrict, and/or monitor flow of, or transfer heat and/or momentum to or from, a fluid, solids, or combinations of fluid and solids. 
   
   
       2 . The downhole apparatus of  claim 1  wherein the DLC coating is deposited by a process selected from PVD, CVD, or any enhanced-plasma CVD process such as the hollow cathode plasma ion immersion process to provide anti-wear, ultra low friction, and environmentally resistant surfaces. 
   
   
       3 . The downhole apparatus of  claim 1  wherein the base metal or alloy is ferrous or non-ferrous and includes oilfield metallic materials such as carbon steels, stainless steels, nickel alloys, and titanium alloys. 
   
   
       4 . The downhole apparatus of  claim 1  with at its surfaces one or more intermediate metallic or semi-metallic layers between the base metal or alloy of  claim 3  and the DLC coating to produce a functionally graded material that permit the formation of an adherent and slick DLC coating. 
   
   
       5 . The downhole apparatus of  claim 4  wherein the intermediate layer comprises a metal, in particular selected from transition-metals and/or carbide-forming elements; for instance silicon, chromium, tantalum, titanium, and combinations thereof. 
   
   
       6 . The downhole apparatus of  claim 1  selected from subsurface safety valves, packers, connectors, submersible pump components, mandrels and components thereof, sensors, blow out preventer components, bottom hole assemblies (BHA) or components thereof, sucker rods, drill string components, valve components, power cables, fiber optic connections and other tools, pressure sealing elements for fluids, and sand-control equipments. 
   
   
       7 . The downhole apparatus of  claim 1  selected from: valves with internal passageways, wherein the valve is selected from safety valves, formation isolation valves, check valves, circulation valves, gas lift valves, and frac valves; hydraulic chamber bores and hydraulic piston bores; flow tube internal surfaces; internal passageways of completion tools; seal bore assemblies; joints; internal surfaces of pumps; bearings in powerdrive tools and drilling tools; control line sections; threads and seal surfaces; external surfaces of internal tubing, collets and like components; nipples; plugs; pressure setting tools; locks; standing valves; shock absorbers; packoffs; control-line protectors; polished bore receptacles; unions; subs; sleeves; and on-off attachments. 
   
   
       8 . A downhole apparatus comprising at least one component comprising an internal surface comprising a base metal or alloy having a DLC coating thereon, the DLC coating present at least on some of the internal surface of the base metal or alloy to be exposed to an downhole environment, the DLC coating derived from PVD, CVD, or an enhanced-plasma CVD process such as the hollow cathode plasma ion immersion process, the apparatus selected from subsurface safety valves, packers, connectors, submersible pump components, mandrels and components thereof, sensors, blow out preventer components, bottom hole assemblies (BHA) or components thereof, sucker rods, drill string components, power cables, fiber optic connections and other tools, pressure sealing elements for fluids, screens, valves having components defining internal passageways, wherein the valve is selected from safety valves, formation isolation valves, check valves, circulation valves, gas lift valves, and frac valves; hydraulic chamber bores and hydraulic piston bores; flow tube internal surfaces; internal passageways of completion tools; seal bore assemblies; joints; internal surfaces of pumps; bearings in powerdrive tools and drilling tools; control line sections; threads and seal surfaces; external surfaces of internal tubing, collets and like components; nipples; plugs; pressure setting tools; locks; standing valves; shock absorbers; packoffs; control-line protectors; polished bore receptacles; unions; subs; sleeves; and on-off attachments. 
   
   
       9 . The downhole apparatus of  claim 8  comprising one or more intermediate metallic layers between the base metal or alloy and the DLC coating, wherein the intermediate layer comprises in particular selected from transition-metals and/or carbide-forming elements; for instance silicon, chromium, tantalum, titanium, and combinations thereof. 
   
   
       10 . A downhole apparatus comprising a hydraulic chamber, the hydraulic chamber having an internal surface defined by a base metal or alloy, at least some of the internal surface having a DLC coating thereon, the DLC coating derived from PVD, CVD, or an enhanced-plasma CVD process such as the hollow cathode plasma ion immersion process. 
   
   
       11 . A downhole flow control apparatus comprising at least one internal passageway, this internal passageway having an internal surface defined by a base metal or alloy, at least some of the internal surface having a DLC coating thereon, the DLC coating derived PVD, CVD, or an enhanced-plasma CVD process such as the hollow cathode plasma ion immersion process. 
   
   
       12 . A downhole pump apparatus comprising at least one component having an internal passageway having an internal surface defined by a base metal or alloy, at least some of the internal surface having a DLC coating thereon, the DLC coating derived from PVD, CVD, or an enhanced-plasma CVD process such as the hollow cathode plasma ion immersion process. 
   
   
       13 . A method comprising:
 (a) selecting a downhole apparatus comprising a base metal or alloy having a DLC coating thereon produced from PVD, CVD, or an enhanced-plasma CVD process such as the hollow cathode plasma ion immersion process, the DLC coating present at least on one or more internal passageways of the base metal or alloy to be exposed to downhole environments, the apparatus selected from downhole tools having one or more of the following functions: control, change, isolate, restrict, and/or monitor flow of, or transfer heat and/or momentum to or from, a fluid, solids, or combinations of fluid and solids; and   (b) deploying and using the downhole apparatus downhole during a downhole operation.   
   
   
       14 . The method of  claim 13  wherein the downhole operation is selected from completion operations, pumping, circulating, acidizing, fracturing, flow diverting and combinations thereof. 
   
   
       15 . The method of  claim 14  wherein the downhole operation is a completion operation, and the downhole apparatus is selected from one or more of packers, connectors, submersible pump components, mandrels and components thereof, sensors, blow out preventer components, bottom hole assemblies (BHA) or components thereof, sucker rods, drill string components, power cables, communication wires and cables, bulkheads such as those used in fiber optic connections and other tools, pressure sealing elements for fluids, screens, valves having components defining internal passageways, wherein the valve is selected from safety valves, formation isolation valves, check valves, circulation valves, gas lift valves, and frac valves; hydraulic chamber bores and hydraulic piston bores; flow tube internal surfaces; internal passageways of completion tools; seal bore assemblies; joints; internal surfaces of pumps; bearings in powerdrive tools and drilling tools; control line sections; threads and seal surfaces; external surfaces of internal tubing, collets and like components; nipples; plugs; pressure setting tools; locks; standing valves; shock absorbers; packoffs; control-line protectors; polished bore receptacles; unions; subs; sleeves; and on-off attachments.