Boronized Slip Bearing Surface for HPHT Corrosion Resistance
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Solution Overview
Problem
Existing downhole tools, particularly permanent packers, face challenges in being easily removable due to their metallic composition, leading to increased rig time and bit tracking issues during milling or drilling, and require improved corrosion resistance in high-pressure and high-temperature oilfield environments.
Innovation Solution
A boronized corrosion-resistant alloy is applied to the bearing surfaces of downhole tool components, such as slips, through a process that forms a metallurgical bond with the base material, enhancing hardness and corrosion resistance by inducing compressive stresses or relieving tensile stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used to construct permanent packer, then strength and load-bearing capability are improved, but milling or drilling time increases significantly
Solution Approach 1:
The packer is divided into two distinct parts: a metallic body providing strength and load-bearing capability, and a non-metallic slip component providing ease of removal. This segmentation allows each part to be made from optimal materials for its specific function, resolving the contradiction between strength and removability.
Solution Approach 2:
The invention uses composite construction combining metallic materials (for strength) with non-metallic materials such as composites, ceramics, or plastics (for ease of milling/drilling). This composite approach allows the packer to achieve both high strength and easy removal by destroying only the non-metallic slip component rather than the entire metallic structure.
2Strength
If metallic materials are used for permanent packer, then load-bearing capability is improved, but bit tracking occurs during drilling
Solution Approach 1:
By separating the slip component from the main packer body and using non-metallic materials for the slip component, the invention eliminates the bit tracking problem that occurs when drilling bits contact metallic surfaces. The non-metallic material does not cause bit tracking while the metallic body maintains load-bearing capability.
Solution Approach 2:
The composite construction with non-metallic slip components eliminates bit tracking during removal operations. Non-metallic materials such as composites, ceramics, and plastics do not exhibit the bit tracking behavior characteristic of metallic materials, while the metallic body portion maintains structural integrity and load-bearing capability.
3Ease of manufacture
If non-metallic materials are used for permanent packer, then ease of milling or drilling is improved, but strength and load-bearing capability decrease
Solution Approach 1:
The packer is segmented into a metallic body that provides strength and a non-metallic slip component that provides ease of removal. This allows the majority of the structure (the body) to be made from strong metallic materials while only the removable portion (the slip component) is made from easily milled non-metallic materials.
Solution Approach 2:
The composite construction combines metallic materials for the main body (providing strength) with non-metallic materials for the slip component (providing ease of milling/drilling). This resolves the contradiction by allowing each material type to be used where its properties are most beneficial.
4Ease of manufacture
If standard steel is used in corrosive environments, then cost is reduced, but corrosion resistance is insufficient for high pressure and high temperature applications
Solution Approach 1:
The invention uses corrosion-resistant alloy materials (such as nickel-based alloys, stainless steels, or titanium alloys) for the metallic components of the packer. These alloy materials provide superior corrosion resistance in high-pressure, high-temperature, and corrosive oilfield environments compared to standard steel, while maintaining structural integrity and load-bearing capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The boronized alloy components demonstrate improved hardness and corrosion resistance, allowing for easier removal and enhanced performance in high-pressure and high-temperature conditions, reducing rig time and preventing bit tracking.
Implementation Method 1
bonding an external layer at least on the bearing surface to form a metallurgical bond between boron from the boron source with the base material by boriding the base material
Implementation Method 2
enhancing hardness and corrosion resistance by inducing compressive stresses or relieving tensile stresses
Data Source
AI summary
A hardened slip and a method of making the hardened slip are disclosed. A method of hard surfacing a slip component for a downhole tool is disclosed. The slip component may have a bearing surface and may be composed of a base material, the base material being metallic. The method may comprise steps of positioning at least the bearing surface of the slip component with a direct contact with a boron source; bonding an external layer at least on the bearing surface to form a metallurgical bond between boron from the boron source with the base material by boriding the base material; and maintaining a bulk temperature of the slip component below a melting point of the base material.