Corrodible Composite Triggering Element for Expandable Borehole Tools

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Solution Overview

Problem

Expandable reamer apparatuses in subterranean boreholes are limited by the need to remove the triggering element, such as a ball, from the drill string to trigger expansion, which allows for only a single use during downhole operations, restricting the ability to enlarge boreholes effectively and increase production flow rates.

Innovation Solution

The use of a corrodible composite material for the triggering element, comprising a discontinuous metallic phase dispersed within a corrodible matrix phase, which can be partially corroded to remove itself from the seat, allowing the expandable apparatus to be triggered multiple times without removing the entire drill string.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a ball triggering system is used in expandable apparatus, then the apparatus can be triggered for expansion, but the ball cannot be removed without removing the entire drill string, limiting the apparatus to single use only

Engineering Contradiction:

ImproveAbility to trigger expandable apparatusVSAvoidReusability of expandable apparatus

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The triggering element's material composition is changed from traditional solid materials to a corrodible composite material containing a corrodible matrix phase (such as zinc, magnesium, or their alloys) dispersed in a continuous phase. This material parameter change enables the triggering element to be selectively corroded and removed through chemical action rather than mechanical removal, allowing the expandable apparatus to be triggered multiple times without removing the entire drill string.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The triggering element is constructed as a composite material system with a corrodible matrix phase (zinc, magnesium, or their alloys) and a continuous phase that provides structural integrity. This composite structure allows the triggering element to maintain sufficient strength for triggering while being selectively removable through corrosion of the matrix phase, thereby enabling repeated use of the expandable apparatus.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the triggering element is made of corrodible composite material, then the apparatus can be triggered multiple times, but the material must maintain high initial strength before corrosion

Engineering Contradiction:

ImproveReusability of expandable apparatusVSAvoidInitial strength of triggering element

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The triggering element employs a composite material architecture where a corrodible matrix phase (zinc, magnesium, or their alloys) is dispersed in a continuous phase that provides structural support. This composite structure ensures the triggering element maintains high initial strength for reliable triggering while the corrodible matrix phase enables selective removal through corrosion, facilitating multiple uses.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The composite material structure provides different properties in different phases: the continuous phase provides high initial strength and structural integrity for triggering, while the dispersed corrodible matrix phase provides selective removability through corrosion. This local differentiation of material properties resolves the contradiction between needing high initial strength and enabling subsequent removal.

Inventive Principle:

Principle #3Local quality

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 the expandable apparatus to be triggered multiple times, maintaining a high initial strength and then selectively corroding to facilitate self-removal, thereby enhancing borehole enlargement capabilities and production flow rates without the need for repeated drill string removal.

Implementation Method 1

a corrodible matrix phase, the metallic phase comprising a metal or metal alloy, the corrodible matrix phase comprising at least one of a ceramic and an intermetallic compound

Methodology Applied

Scientific EffectCorrosion: Crevice Corrosion

Data Source

PatentUS10576544B2Methods of forming triggering elements for expandable apparatus for use in subterranean boreholes

Publication Date: 2020.03.03 BAKER HUGHES CO

AI summary

Expandable apparatus include a triggering element comprising an at least partially corrodible composite material. Methods are used to trigger expandable apparatus using such a triggering element and to form such triggering elements for use with expandable apparatus.