Carbide Shaped Charge Liner for Perforation Hole Erosion Control

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Solution Overview

Problem

Hydraulic fracturing operations face challenges due to erosion of perforation holes in wellbore casings caused by abrasive sand grains in slurry fluids, leading to variations in flow rates and pressures, which can affect the efficiency and uniformity of fracture growth.

Innovation Solution

A shaped charge liner formed from a powder blend, including erosion-resistant materials like tungsten carbide, is used to create a perforating jet that deposits a hard material around and within the perforation hole, maintaining its diameter and enhancing wear resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sand grains are pumped into the fracture to keep it open, then the fracture remains propped open, but the sand grains erode the perforation hole edge causing diameter increase and flow rate variation

Engineering Contradiction:

Improvefracture propping effectivenessVSAvoidperforation hole erosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by forming a hardened erosion-resistant coating on the inner surface of the perforation hole before the sand grains are pumped into the fracture. This pre-protection measure ensures that when propping sand is introduced to keep the fracture open, the perforation hole edge is already protected against erosive damage, maintaining consistent flow rates and preventing diameter increase

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful erosive action of high-velocity fluids into a beneficial process by utilizing the same fluid flow to deposit and harden an erosion-resistant coating on the perforation hole interior. The harmful sand grains that would normally cause erosion are instead used to abrade and embed erosion-resistant material into the hole surface, transforming the erosive force into a protective mechanism

Inventive Principle:

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

2Productivity

If the perforation hole diameter increases due to erosion, then flow rate increases, but pressure drop increases and fracture growth uniformity decreases

Engineering Contradiction:

Improveflow rateVSAvoidperforation hole diameter consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements feedback by monitoring the flow characteristics and pressure differential across the perforation hole during hydraulic fracturing operations. When erosion begins to alter the hole diameter, the system detects changes in flow rate and pressure drop, and automatically adjusts operational parameters or activates additional protective mechanisms to maintain the desired diameter consistency and uniform fracture growth

Inventive Principle:

Principle #23Feedback

3Ease of operation

If conventional liners are used, then the shaped charge creates perforation holes, but the liners erode quickly under high-velocity slurry flow

Engineering Contradiction:

Improveperforation capabilityVSAvoidliner service life

Core Design Contradiction:

Ease of operationVSDuration of action of stationary object

Solution Approach 1:

The patent applies composite materials by creating a liner structure that combines a base material with a hardened erosion-resistant coating layer. The composite construction integrates the structural integrity of the base liner with the superior erosion resistance of the coating, enabling the liner to withstand high-velocity slurry flow and maintain its functionality throughout the entire hydraulic fracturing operation without premature failure

Inventive Principle:

Principle #40Composite materials

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 erosion-resistant liner maintains consistent flow rates and pressures during hydraulic fracturing by reducing the erosion of wellbore casings, ensuring uniform fracture growth and operational efficiency.

Implementation Method 1

When the detonating cord initiates the explosive load within the shaped charge, a liner, and/or other materials within the shaped charge are collapsed and propelled out of the shaped charge in a perforating jet of thermal energy and solid material

Methodology Applied

Scientific EffectExplosion: Explosion

Implementation Method 2

Shaped charges are explosive components configured to focus ballistic energy onto a target

Methodology Applied

Scientific EffectShaped charge: Shaped Charge

Implementation Method 3

the sand grains in the slurry fluid constantly act as an abrasive against the edge of perforation holes in the wellbore casing and slowly erode the hole

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 4

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS20250216180A1Shaped charge liner to reduce hydraulic induced erosion on perforating holes

Publication Date: 2025.07.03 DYNAENERGETICS EURO GMBH

AI summary

A liner for a shaped charge is formed from a powder blend and dimensioned for forming a perforating jet to create a hole in a target in response to detonation of an explosive. The powder blend includes an erosion resistant material. The erosion resistant material is a powdered carbide material, a powdered nitride material, or a cobalt powder material.