Curved-Housing Explosive Downhole Tools for Conveyance, Low Debris

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Solution Overview

Problem

Conventional explosive downhole tools often get stuck in wellbores due to sharp corners catching on restrictions, and they generate debris that obstructs further operations, while larger explosive units are difficult to transport due to regulatory constraints.

Innovation Solution

The design includes rounded housing surfaces and fins to facilitate conveyance, uses dissolvable materials to minimize debris, and employs a configuration with multiple explosive charges to create protrusions without puncturing, and incorporates inert material to reduce radial explosive energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional explosive downhole tools with sharp corners are used, then cutting effectiveness is improved, but the tools get stuck on wellbore restrictions

Engineering Contradiction:

Improvecutting effectivenessVSAvoidconveyance through wellbore

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The housing of the explosive downhole tool is designed with rounded external surfaces and curved transitions instead of sharp corners. This curvature allows the tool to navigate wellbore restrictions, ledges, and irregularities without catching or getting stuck, while maintaining structural integrity and cutting functionality.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Productivity

If conventional explosive tools are used, then operational capability is maintained, but debris is generated that obstructs further operations

Engineering Contradiction:

Improveoperational capabilityVSAvoiddebris generation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The housing material is changed from conventional metal to a dissolvable material that breaks down after serving its function. This parameter change in material properties allows the housing to maintain structural integrity during operation and then decompose into manageable fragments that do not obstruct further wellbore operations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The housing is designed as a disposable component made of dissolvable material that completes its function and then breaks down. This eliminates the need for expensive retrieval operations and prevents debris obstruction, as the housing fragments dissolve or break into manageable pieces after use.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Power

If larger explosive units are used to increase power, then cutting capability is improved, but transportation becomes difficult due to regulatory constraints

Engineering Contradiction:

Improvecutting capabilityVSAvoidtransportation compliance

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The explosive charge is divided into multiple separate units or segments that can be transported independently in compliance with regulatory size and weight limits. These segmented explosive units are then assembled at the wellsite to form the complete high-power charge required for effective cutting operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The explosive units are prepared and segmented in advance for compliant transportation, then assembled into the complete charge configuration at the wellsite before deployment. This preliminary segmentation allows regulatory compliance during transport while maintaining full cutting capability at the operation site.

Inventive Principle:

Principle #10Preliminary action

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 tool easily navigates wellbore restrictions, minimizes debris, and complies with transportation regulations by using safer, larger explosive units, enhancing operational efficiency and safety.

Implementation Method 1

a first explosive charge comprising a predetermined amount of explosive material for generating at least a first radial explosive wave front that: (i) cuts the wall of the tubular; or (ii) expands, without puncturing, the wall of the tubular

Methodology Applied

Scientific EffectExplosion: Explosion

Implementation Method 2

uses dissolvable materials to minimize debris

Methodology Applied

Scientific EffectDissolution:

Implementation Method 3

incorporates inert material to reduce radial explosive energy

Methodology Applied

Scientific EffectEnergy absorption:

Data Source

PatentUS12392211B2Explosive downhole tools having improved wellbore conveyance and debris properties, methods of using the explosive downhole tools in a wellbore, and explosive units for explosive column tools

Publication Date: 2025.08.19 W T BELL INT INC

AI summary

An explosive downhole tool includes a housing having an upper housing part on one side of a window section and a lower housing part on an opposite side of the window section. An explosive charge is provided within the housing for cutting or expanding the wall of the tubular. The majority of outer surface of at least one of the upper and lower housing part in cross-section is rounded so as to be devoid of corners. The rounded surface eliminates the presence of sharp corners that may catch on restrictions or protrusions in a wellbore so that the downhole tool is more easily conveyable within a wellbore. Another explosive downhole tool includes fins extending from the housing. The fins have a height that decreases in a direction away from the housing. The shape of the fins enables the downhole tool to be more easily conveyable within the wellbore.