Dissolvable Downhole Tool with Brittle Protective Coating

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Solution Overview

Problem

Dissolvable plugs used in oilfield fracturing operations often experience premature dissolving during deployment or before setting, requiring additional protective materials and costly abrasive removal processes to delay dissolution.

Innovation Solution

A downhole tool with a dissolvable component and a protective coating that fractures upon deformation, exposing the component to wellbore fluids and initiating dissolution, eliminating the need for separate abrasive removal processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If dissolvable plugs are used to eliminate milling operations, then productivity and cost are improved, but the plugs experience premature dissolving during deployment and setting

Engineering Contradiction:

Improveelimination of milling operationsVSAvoidpremature dissolving during deployment

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A protective coating is applied to the dissolvable plug before deployment to prevent premature dissolution. The coating remains intact during run-in and setting operations, and is then removed by deformation at the setting location, allowing the plug to dissolve at the appropriate time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protective coating acts as an intermediary layer between the dissolvable plug and the wellbore environment. This intermediate layer prevents direct contact between the dissolvable material and wellbore fluids during deployment, while allowing controlled exposure after setting through deformation-induced coating failure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If protective materials are applied to delay dissolution, then reliability is improved, but device complexity and operational complexity increase due to additional abrasive removal processes

Engineering Contradiction:

Improvedelay of dissolution until settingVSAvoidadditional abrasive removal processes

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective coating is designed to self-remove through deformation of the dissolvable plug body during the setting process. The cone deformation mechanism automatically fractures and removes the coating without requiring separate abrasive removal operations, making the system self-servicing.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The coating removal function is merged with the setting operation. The same deformation mechanism that sets the plug (advancing the cone to deform the plug body) also simultaneously removes the protective coating, combining two operations into one.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the protective coating is made durable to prevent premature dissolution, then reliability is improved, but the coating becomes difficult to remove without abrasive processes

Engineering Contradiction:

Improveprotection during run-inVSAvoiddifficulty of coating removal

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The protective coating has different mechanical properties than the dissolvable plug body. The coating is designed to be relatively brittle compared to the more ductile plug material, allowing it to fracture and flake off when the plug is deformed during setting, while still providing adequate protection during run-in.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The interaction between the protective coating and the dissolvable plug changes dynamically during the operational sequence. During run-in, the coating provides rigid protection. During setting, the deformation of the plug body creates dynamic mechanical stress that exceeds the coating's fracture strength, causing automatic removal.

Inventive Principle:

Principle #15Dynamics

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 solution ensures reliable deployment and setting of the downhole tool by preventing premature dissolution during run-in and facilitating efficient dissolution upon deformation, reducing operational costs and complexity.

Implementation Method 1

The protective coating is configured to isolate the component from the wellbore fluid

Methodology Applied

Scientific EffectPhysical barrier isolation:

Implementation Method 2

the protective coating is configured to... fracture in response to the component deforming

Methodology Applied

Scientific EffectMechanical fracture: Fracture Mechanics

Implementation Method 3

a component that is configured to dissolve in a wellbore fluid

Methodology Applied

Scientific EffectChemical dissolution:

Data Source

PatentUS11125039B2Deformable downhole tool with dissolvable element and brittle protective layer

Publication Date: 2021.09.21 INNOVEX DOWNHOLE SOLUTIONS LLC

AI summary

A downhole tool includes a component that is configured to dissolve in a wellbore fluid, and a protective coating applied to the component. The protective coating is configured to isolate the component from the wellbore fluid, and to fracture in response to the component deforming and expose the component to the wellbore fluid.