Degradable Abrasive Grit for Erosive Jet Cutting
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Solution Overview
Problem
In downhole oilfield operations, abrasive grit used in erosive jet cutting can settle and cause equipment damage, clogging, and safety hazards due to its inability to degrade effectively in the wellbore environment, leading to increased risks and operational inefficiencies.
Innovation Solution
The use of degradable abrasive grit conveyed in a carrier fluid, where the grit is composed of metal and/or plastic components that degrade through corrosion or dissolution, with a degradation accelerator introduced to control the degradation rate, ensuring the grit remains effective during cutting operations and avoids post-operation complications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If abrasive grit is used in erosive jet cutting operations, then cutting efficiency and erosion capability are improved, but the abrasive grit settles in the wellbore causing equipment damage, clogging, and safety hazards
Solution Approach 1:
The abrasive grit material composition is changed from conventional non-degradable materials (such as silica or alumina) to degradable materials that break down in the downhole environment. This parameter change allows the abrasive to maintain its cutting effectiveness during the operation while subsequently degrading to avoid settlement problems, equipment damage, and clogging in the wellbore.
Solution Approach 2:
The patent employs disposable abrasive grit particles made from degradable materials that are designed to be used once and then break down naturally in the downhole environment. These short-living abrasive particles perform their cutting function and then degrade, eliminating the need for retrieval and avoiding the problems associated with reusable abrasive that would settle and cause hazards.
2Strength
If conventional abrasive grit is used, then erosion capability is enhanced, but it causes plugging of screens and interference with sliding tools
Solution Approach 1:
The material parameters of the abrasive grit are changed to include degradable components that break down in the downhole fluid environment. This allows the abrasive to maintain high erosion capability during cutting operations while subsequently degrading to prevent plugging of screens and interference with sliding tools, thereby improving tool mobility and ease of operation.
3Productivity
If abrasive grit remains intact after cutting operation, then cutting efficiency is maintained, but it creates residue build-up and clogging in the wellbore formation
Solution Approach 1:
The abrasive grit is designed as a short-living material that completes its cutting function and then degrades in the downhole environment. This disposable approach ensures that after the cutting operation is complete, the abrasive particles break down and dissolve, preventing residue build-up and clogging in the wellbore formation while maintaining cutting efficiency during the operational phase.
Solution Approach 2:
The potential harm of abrasive grit settling and causing clogging is converted into a benefit by designing the abrasive to degrade naturally in the downhole environment. The degradation process, which could be seen as a loss of abrasive effectiveness, is actually beneficial as it eliminates residue build-up and prevents clogging, while the abrasive maintains its cutting efficiency during the operational period.
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
This solution enhances cutting efficiency while preventing clogging and equipment damage by ensuring the abrasive grit degrades in the wellbore fluid, reducing operational risks and improving safety and efficiency in downhole operations.
Implementation Method 1
The abrasive grit can degrade or dissolve in the wellbore fluid (e.g., in carrier fluid pumped into the wellbore or in fluid originating from the wellbore)
Implementation Method 2
The abrasive grit can degrade or dissolve in the wellbore fluid
Implementation Method 3
a fluid (e.g., water) that is pumped through a nozzle at a pressure high enough to erode a targeted material
Implementation Method 4
erosive jet cutting (e.g., waterjet cutting) apparatuses can be used to cut through materials
Data Source
AI summary
An erosive jet can propel degradable, abrasive grit conveyed in a carrier fluid to erode a downhole structure, such as a tubular (e.g., cutting through a tubular) or formation (e.g., perforation actions). The abrasive grit can be selected to degrade or dissolve in the wellbore fluid (e.g., in carrier fluid pumped into the wellbore or in fluid originating from the wellbore). The abrasive grit can provide increased cutting or erosion efficiency in the erosive jet during the cutting operation, then may degrade (e.g., dissolve) in the wellbore fluid to avoid certain complications, such as clogging or residue build-up in the wellbore formation or on downhole equipment. A degradation accelerator can be introduced (e.g., in carrier fluid) to accelerate degradation of the abrasive grit in the wellbore fluid. Degradation accelerators can be temperature-activated, pH-activated, or otherwise time-delayed so the abrasive grit remains sufficiently intact to perform the desired erosion operation.