Carbide-Shaped Charge Liner for Erosion-Resistant Perforation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Hydraulic fracturing operations face challenges due to erosion of perforation holes in wellbore casings, leading to inconsistent pressure and flow rates, and difficulties in accurately imaging and identifying perforation holes, which affects the efficiency and reliability of the fracturing process.

Innovation Solution

A shaped charge liner with a carbide or metal nitride layer is used to create perforation holes with increased wear resistance and visibility, featuring a carbide or nitride material that bonds to the surface of the perforation hole upon detonation, forming a halo that enhances erosion resistance and visibility for imaging devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional shaped charges are used to create perforation holes, then the perforation process is simple and fast, but the perforation holes suffer from erosion and corrosion leading to inconsistent pressure and flow rates

Engineering Contradiction:

Improveperforation hole consistencyVSAvoidshaped charge structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The shaped charge liner is constructed from composite materials including carbide (such as tungsten carbide) and metal nitride (such as titanium nitride) layers combined with traditional explosive materials. This composite structure enables the liner to produce a jet that deposits erodible-resistant material onto the perforation hole surfaces, thereby protecting against erosion and corrosion while maintaining structural integrity and consistent performance throughout the hydraulic fracturing process.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the material parameters of the shaped charge liner by incorporating high-hardness materials like carbide and metal nitride. These material parameter changes enable the liner to withstand erosive forces and maintain consistent perforation hole geometry, resulting in reliable pressure and flow rates during hydraulic fracturing operations.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If standard liners are used in shaped charges, then the manufacturing process is simple, but the perforation holes are not visible to imaging devices

Engineering Contradiction:

Improveperforation hole visibilityVSAvoidliner manufacturing

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The carbide and metal nitride materials in the shaped charge liner create a distinct visual contrast or 'halo' effect around the perforation holes when deposited on the casing surface. This color/reflectivity change makes the perforation holes clearly visible to imaging devices, enabling precise measurement and verification of perforation quality without complicating the manufacturing process.

Inventive Principle:

Principle #32Color changes

3Productivity

If conventional shaped charges are used, then the operation is straightforward, but erosion of perforation holes leads to lost hydraulic fracturing efficiency

Engineering Contradiction:

Improvehydraulic fracturing efficiencyVSAvoidperforation hole erosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention converts the erosive forces present during hydraulic fracturing into a beneficial effect. The high-velocity jet generated by the shaped charge carries carbide and metal nitride materials that deposit onto the perforation hole surfaces, creating a protective coating. This transforms the potentially harmful erosion into a self-healing process where the same fluid flow that causes erosion also deposits protective material, thereby maintaining hydraulic fracturing efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution effectively reduces erosion and corrosion of perforation holes, maintaining consistent hole sizes and improving the visibility of perforation holes for imaging, thereby enhancing the operational efficiency and reliability of hydraulic fracturing processes.

Implementation Method 1

a carbide or nitride material supplied by the shaped charge liner bonds to a surface of the perforation hole upon detonation of the shaped charge

Methodology Applied

Scientific EffectBonding: Chemical Bonding

Implementation Method 2

The halo formed by the carbide or nitride material significantly increases erosion resistance of the perforation hole

Methodology Applied

Scientific EffectErosion resistance: Erosion

Data Source

PatentUS11255168B2Perforating system with an embedded casing coating and erosion protection liner

Publication Date: 2022.02.22 DYNAENERGETICS EURO GMBH

AI summary

A shaped charge liner may include an apex portion and a skirt portion extending from the apex portion. The skirt portion may include a body connected to the apex portion, a perimeter spaced apart from the apex portion, and a carbide layer extending between and spaced apart from the perimeter and the apex portion. A shaped charge for creating a perforation hole in a wellbore casing may include a shaped charge liner having at least one material having hardness that is greater than a corresponding hardness of the wellbore casing. The at least one material is configured to bond to at least one of an outer surface and an inner surface of the perforation hole upon detonation of the shaped charge and penetration of the casing by a perforation jet.