Corrodible Shaped Charge Liner for Wellbore Perforation
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Solution Overview
Problem
Current perforating systems for wellbores leave residual liner material in perforations, reducing efficiency and requiring costly and time-consuming removal processes.
Innovation Solution
A selectively corrodible perforating system using shaped charges with charge cases and liners made from corrodible powder compact materials, which can be dissolved or removed by wellbore fluids, allowing for efficient removal of residues and system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If traditional metal liners are used in shaped charges, then the perforation penetration depth is improved, but liner residue remains in the perforation reducing efficiency
Solution Approach 1:
The patent changes the material parameter of the liner from traditional metal to a corrodible material such as sugar, salt, starch, or gelatin. This parameter change allows the liner to dissolve completely after perforation, eliminating residue that blocks hydraulic flow while maintaining the penetration capability through proper explosive charge design
Solution Approach 2:
The patent employs disposable liners made from inexpensive, biodegradable materials that serve their purpose during the perforation process and then dissolve away. These short-living liners are replaced naturally through dissolution by formation fluids or injection fluids, eliminating the need for permanent structural components that would create residue
2Productivity
If shaped charge guns are fired to create perforations, then hydraulic communication passages are formed, but additional costly and time-consuming removal operations are required to remove components from the wellbore
Solution Approach 1:
The patent makes the charge case and other components self-removing through their design as corrodible materials. After the shaped charge fires and creates the perforation, the charge case automatically dissolves in the formation fluids or injection fluids without requiring any additional removal operations by drilling or fishing tools
Solution Approach 2:
The patent is designed to discard the charge case and liner materials after they have served their perforation function. The corrodible materials are intentionally left in the wellbore to dissolve naturally, converting the removal process from an active mechanical operation to a passive chemical dissolution process that occurs over time
3Ease of operation
If corrodible powder compact materials are used for charge case and liner, then component removal is simplified, but the structural integrity during detonation must be maintained
Solution Approach 1:
The patent uses composite material structures where corrodible powders are compacted into dense configurations that provide temporary structural strength during the high-stress detonation event. The compacted powder structure maintains integrity under explosive forces but dissolves readily afterward when exposed to formation or injection fluids
Solution Approach 2:
The patent changes the physical state parameter of the corrodible materials from loose powder to densely compacted forms. This parameter change increases the material's strength and rigidity during the detonation process while preserving its ability to dissolve after the operation is complete
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 unhindered fluid flow through perforations, increases well productivity, and simplifies the removal of perforating system components, reducing operational costs and time.
Implementation Method 1
A high explosive is detonated to collapse the liner and ejects it from one end of the shaped charge at a very high velocity
Implementation Method 2
A perforating gun string may be lowered into the well and one or more guns fired to create openings in the casing and/or a cement liner and to extend perforations into the surrounding formation
Implementation Method 3
exposing the perforation gun and perforation tunnel to a predetermined wellbore fluid after detonating the shaped charge to remove a liner residue from the perforation tunnel and the charge case from the well
Data Source
AI summary
A method for perforating a formation interval in a well is disclosed. The method includes disposing a perforation gun comprising a shaped charge in the well proximate the formation interval, wherein the shaped charge comprises a charge case having a charge cavity, a liner disposed within the charge cavity and an explosive disposed within the charge cavity between the liner and the charge case, wherein the charge case and liner are each formed from a selectively corrodible powder compact material. The method also includes detonating the shaped charge to form a perforation tunnel in the formation interval and deposit a liner residue in the perforation tunnel The method further includes exposing the perforation gun and perforation tunnel to a predetermined wellbore fluid after detonating the shaped charge to remove a liner residue from the perforation tunnel and the charge case from the well.