Disintegratable Polymer Composites for Downhole Tool Removal

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Solution Overview

Problem

Downhole constructions in oil and natural gas wells face challenges with the disposal of borehole components and tools, as existing methods like milling and drilling are time-consuming and expensive, necessitating new materials and methods for removal without these operations.

Innovation Solution

A disintegrable polymer composite comprising a polymer component such as cured cyanate ester, crosslinked unsaturated polyester, or crosslinked vinyl ester resin, combined with dissolvable glass, which dissolves in wellbore fluids at elevated temperatures, allowing for controlled disintegration and removal of downhole tools or components without mechanical or hydraulic forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional milling or drilling methods are used to remove downhole components, then the component can be removed from the borehole, but the process is time-consuming and expensive

Engineering Contradiction:

Improvecomponent removal speedVSAvoidtime for milling or drilling operations

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent changes the material parameters of the downhole component by using a polymer composite specifically formulated to dissolve in wellbore fluids. This chemical property change allows the component to disintegrate automatically when exposed to the fluid environment, eliminating the need for mechanical removal operations and significantly reducing both time and cost.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies the disposable principle by designing a downhole component made from a dissolvable polymer composite that is intended to be temporary. The component performs its function and then naturally disintegrates in the wellbore fluid, replacing the need for expensive and time-consuming removal operations with a simple, low-cost dissolution process.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Productivity

If traditional milling or drilling methods are used to remove downhole components, then the component can be removed from the borehole, but the process is expensive

Engineering Contradiction:

Improvecomponent removal efficiencyVSAvoidcost of removal operations

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent applies self-service by enabling the downhole component to remove itself from the borehole through automatic dissolution in the wellbore fluid. The component's material composition allows it to naturally disintegrate when exposed to the fluid environment, eliminating the need for external removal equipment or operations and significantly reducing costs.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If a polymer composite is designed to dissolve in wellbore fluids, then removal without milling or drilling is achieved, but the material must maintain structural integrity during service

Engineering Contradiction:

Improvesimplicity of removal processVSAvoidtensile strength and collapse pressure

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent applies composite materials by combining polymer components with specific chemical compositions that provide both structural strength during service and controlled dissolution capability. The composite structure allows the material to maintain mechanical integrity when needed while containing the chemical properties necessary for dissolution in wellbore fluids, thus resolving the contradiction between strength and ease of removal.

Inventive Principle:

Principle #40Composite materials

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 polymer composite provides high tensile strength and collapse pressure, with controlled dissolution in wellbore fluids, enabling efficient and cost-effective removal of downhole tools by degrading and breaking up in wellbore fluids at elevated temperatures, thus simplifying the disposal process.

Implementation Method 1

dissolvable glass, which dissolves in wellbore fluids at elevated temperatures

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

dissolves in wellbore fluids at elevated temperatures, allowing for controlled disintegration

Methodology Applied

Scientific EffectThermal dissolution: Hydrolysis

Data Source

PatentUS10458197B2Disintegratable polymer composites for downhole tools

Publication Date: 2019.10.29 BAKER HUGHES CO

AI summary

A disintegrable polymer composite comprises: a polymer component comprising one or more of the following: a cured cyanate ester; a crosslinked unsaturated polyester; or a crosslinked vinyl ester resin; and dissolvable glass comprising about 55 to about 80 wt. % of SiO2, 0 to about 35 wt. % of Na2O, 0 to about 35 wt. % of K2O, 0 to about 20 wt. % of CaO, 0 to about 10 wt. % of MgO, provided that the sum of the weights of Na2O and K2O is about 20 wt. % to about 40 wt. %, wherein each weight percent is based on the total weight of the dissolvable glass.