Ceramic Disk Rupture via Fluid Jetting

Solution Overview

Problem

Conventional methods for breaching ceramic disks in wellbores during hydrocarbon well drilling and completion are inefficient, causing equipment damage, delays, and complications, especially in non-linear wellbores, due to the use of heavy milling tools and physical contact, which can result in tool breakage or getting stuck.

Innovation Solution

A method and system utilizing a jetting device that directs high-pressure fluid with entrained solids at the ceramic disk to achieve structural failure without physical contact, allowing for non-contact breaking and reducing the risk of tool damage or sticking, suitable for deviated and horizontal wells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional milling tools are used to breach ceramic disks, then the ceramic disk can be broken, but the risk of tool breakage and getting stuck increases

Engineering Contradiction:

Improvetool reliabilityVSAvoidtool damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical milling system with a hydraulic jetting system. High-pressure fluid (water or drilling fluid) is used to erode and breach the ceramic disk instead of mechanical contact with milling tools. This substitution eliminates the physical contact between tools and the ceramic disk, thereby preventing tool breakage and sticking while still achieving the goal of breaching the disk.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs hydraulic jetting using high-pressure fluid streams to breach the ceramic disk. The system uses a pump to generate high-pressure fluid that is directed through a nozzle at the ceramic disk, using hydraulic energy to erode and break through the disk without mechanical contact. This hydraulic approach replaces the mechanical milling process and eliminates the associated tool damage risks.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Productivity

If milling tools are used to breach ceramic disks, then the disk can be broken, but the time and energy required increases

Engineering Contradiction:

Improvebreaching efficiencyVSAvoidtool transit time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces the mechanical milling system with a hydraulic jetting system. High-pressure fluid (water or drilling fluid) is used to erode and breach the ceramic disk instead of mechanical contact with milling tools. This substitution eliminates the physical contact between tools and the ceramic disk, thereby preventing tool breakage and sticking while still achieving the goal of breaching the disk.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs hydraulic jetting using high-pressure fluid streams to breach the ceramic disk. The system uses a pump to generate high-pressure fluid that is directed through a nozzle at the ceramic disk, using hydraulic energy to erode and break through the disk without mechanical contact. This hydraulic approach replaces the mechanical milling process and eliminates the associated tool damage risks.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Productivity

If conventional milling tools are used, then ceramic disks can be breached, but debris formation in the wellbore occurs

Engineering Contradiction:

Improvedisk breaching capabilityVSAvoiddebris formation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical milling system with a hydraulic jetting system. High-pressure fluid (water or drilling fluid) is used to erode and breach the ceramic disk instead of mechanical contact with milling tools. This substitution eliminates the physical contact between tools and the ceramic disk, thereby preventing tool breakage and sticking while still achieving the goal of breaching the disk.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs hydraulic jetting using high-pressure fluid streams to breach the ceramic disk. The system uses a pump to generate high-pressure fluid that is directed through a nozzle at the ceramic disk, using hydraulic energy to erode and break through the disk without mechanical contact. This hydraulic approach replaces the mechanical milling process and eliminates the associated tool damage risks.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 method effectively breaches ceramic disks with reduced risk of tool damage and complications, enabling efficient pressure release and allowing for longer-distance intervention without the need for heavy milling tools, suitable for various wellbore configurations.

Implementation Method 1

directing high pressure fluids with entrained solids at the ceramic disk until structural failure

Methodology Applied

Scientific EffectJet erosion: Jet Erosion

Implementation Method 2

The jetting device is operable to generate a pressurized jet of jetting fluid having a jet pressure

Methodology Applied

Scientific EffectHigh pressure fluid jetting: Jet

Data Source

PatentUS11519235B1Downhole ceramic disk rupture by jetting with fluids and solids

Publication Date: 2022.12.06 SAUDI ARABIAN OIL CO

AI summary

Methods and systems are provided removing the functionality of a ceramic disk installed in a wellbore during oil and gas well completion and production activities. More specifically, the disclosure relates to rupturing a ceramic disk with a jet of fluids. The jetting fluid is directed towards the disk with a jetting device lowered into the wellbore. The jetting fluid comprising a fluid with entrained solids.