Circular Cutting Torch Radial Deflector for Clean Pipe Severing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing downhole cutting tools, such as explosive shaped charges and thermal cutting torches, often deform or leave debris in the wellbore, complicating pipe retrieval during drilling operations, especially in high-pressure oil and gas wells where drilling mud interferes with mechanical parts.

Innovation Solution

A circular cutting torch with a thermal igniter assembly, a compressed grain magazine, and a severing head assembly featuring a one-piece severing head and progressive compression deflector, which uses nonexplosive combustible material to achieve a clean cut by redirecting molten material radially, minimizing deformation and debris.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If explosive shaped charges are used to sever the pipe, then the pipe can be cut, but the pipe may swell, crack, or deform and debris is left in the wellbore

Engineering Contradiction:

Improvecutting efficiencyVSAvoidcut quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical explosive cutting system with a thermal cutting system that uses a combustible material to burn through the pipe. The thermal energy from the burning combustible material melts and vaporizes the pipe material, achieving a clean cut without the mechanical deformation and debris associated with explosive cutting.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the cutting mechanism from mechanical (explosive force) to thermal (combustion temperature). The combustible material burns at high temperature to melt and vaporize the pipe material, transforming the cutting process parameters from mechanical stress to thermal energy to achieve clean cutting without deformation.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If thermal cutting torches are used to burn through the pipe, then a clean cut is achieved, but drilling mud interferes with mechanical moving parts

Engineering Contradiction:

Improvecut qualityVSAvoiddrilling mud interference

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent removes the mechanical moving parts from the thermal cutting torch design that were susceptible to drilling mud interference. By eliminating these mechanical components, the system achieves clean thermal cutting without the harmful effects of drilling mud contamination on mechanical elements.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a disposable combustible material that is consumed during the cutting process. This consumable material provides the thermal energy needed for clean cutting without requiring durable mechanical moving parts that would be susceptible to drilling mud interference.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If explosive cutters are used, then the pipe can be severed, but debris is left in the wellbore causing retrieval difficulties

Engineering Contradiction:

Improvecutting capabilityVSAvoidpipe retrieval

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent replaces the mechanical explosive cutting system with a thermal combustion system. The combustible material burns to melt and vaporize the pipe material, producing minimal debris compared to explosive cutting, thereby facilitating easier pipe retrieval after cutting.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 circular cutting torch provides a clean, efficient cut that maintains the pipe's original diameter, reducing retrieval difficulties and avoiding interference from drilling mud, while withstanding high pressures and temperatures.

Implementation Method 1

uses nonexplosive combustible material to achieve a clean cut

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

redirecting molten material radially

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

redirecting molten material radially, minimizing deformation and debris

Methodology Applied

Scientific EffectFluid flow redirection:

Implementation Method 4

The one-piece severing head and progressive compression deflector may define a radial gap therebetween

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11560765B2Downhole circular cutting torch

Publication Date: 2023.01.24 CHAMMAS PLASMA CUTTERS LLC

AI summary

A circular cutting torch includes a thermal igniter assembly; a compressed grain magazine, the compressed grain magazine coupled to the thermal igniter; and a severing head assembly. The severing head assembly includes a one-piece severing head and a progressive compression deflector. The one-piece severing head and progressive compression deflector define a radial gap therebetween used to expel a jet of molten combustible material for cutting a downhole tubular member such as pipe or casing.