Consumable Downhole Tool Self-Removal via Thermite Torch
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Solution Overview
Problem
Conventional methods for removing disposable downhole tools from well bores are time-consuming and expensive, often requiring milling or drilling, and can be inconsistent when using explosives.
Innovation Solution
A consumable downhole tool made of materials like magnesium that burn away when exposed to heat and oxygen, combined with a torch using a non-explosive fuel load such as thermite to produce heat and oxygen, allowing the tool to self-destruct and fall out of the well bore without mechanical removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional milling or drilling methods are used to remove disposable downhole tools, then the tools can be removed from the well bore, but the operation is time-consuming and expensive
Solution Approach 1:
The patent replaces mechanical removal methods (milling or drilling) with a chemical consumption method. The downhole tool body is made of consumable material that can be burned away by a torch, converting mechanical removal into a chemical process that eliminates the need for complex mechanical equipment and reduces removal time
Solution Approach 2:
The patent changes the physical-chemical parameters of the tool body material from non-consumable to consumable. By using materials that can be burned (such as certain metals or composites), the tool can be selectively consumed by applying heat and oxygen, enabling rapid removal without mechanical intervention
2Productivity
If explosives are used to fragment the downhole tool, then mechanical removal equipment is avoided, but the results are inconsistent
Solution Approach 1:
The patent replaces the explosive fragmentation method with a controlled chemical consumption process. Instead of using explosives to shatter the tool, a torch systematically burns away the consumable material, providing a more predictable and consistent removal process while maintaining high productivity
Solution Approach 2:
The downhole tool is designed with self-consuming capabilities. The tool body material is selected to be consumable by the torch, allowing the tool to essentially remove itself through controlled combustion without requiring external fragmentation forces
3Device complexity
If consumable material is used for the downhole tool body, then mechanical removal is eliminated, but the tool must be reliably consumed without leaving debris
Solution Approach 1:
The patent carefully selects and controls the material parameters of the tool body to ensure complete consumption. By choosing materials with specific combustion characteristics and controlling the torch parameters (temperature, oxygen supply, exposure time), the system achieves reliable complete consumption without leaving problematic debris
Solution Approach 2:
The patent applies different material properties to different parts of the tool as needed. The tool body is made of consumable material while certain critical components may use different materials or protective coatings, allowing selective consumption where needed while maintaining structural integrity where required
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
Enables reliable and cost-effective removal of downhole tools without the need for milling or drilling, reducing operational time and avoiding the complexities of handling explosives.
Implementation Method 1
a torch with a fuel load that produces the heat and source of oxygen when burned
Implementation Method 2
the material comprises a metal, and the metal may comprise magnesium, such that the magnesium metal is converted to magnesium oxide when exposed to heat and a source of oxygen
Implementation Method 3
the firing mechanism comprises a device to activate the heat source
Data Source
AI summary
A downhole tool having a body or structural component comprises a material that is at least partially consumed when exposed to heat and a source of oxygen. The material may comprise a metal, such as magnesium, which is converted to magnesium oxide when exposed to heat and a source of oxygen. The downhole tool may further comprise a torch with a fuel load that produces the heat and source of oxygen when burned. The fuel load may comprise a flammable, non-explosive solid, such as thermite.