Dissolvable Downhole Tool Components for Wellbore Isolation
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Solution Overview
Problem
Conventional downhole tools used for wellbore isolation face challenges such as difficulty in removal due to debris accumulation, high material costs, and the need for complex and time-consuming drill-through operations, especially under extreme wellbore conditions.
Innovation Solution
The development of a downhole tool with components made from composite or dissolvable materials, including reactive metallic materials, that can be easily drilled through or dissolve under specific downhole conditions, reducing the need for extensive removal processes and minimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials (metal, composite) are used for downhole tool components, then strength and durability under extreme conditions are improved, but material cost and difficulty of removal increase
Solution Approach 1:
The patent applies composite materials by combining dissolvable material (e.g., soluble metal like zinc alloy or biodegradable polymer) with reactive metallic material (e.g., iron powder) in a layered structure. The dissolvable material provides initial structural integrity and strength to withstand extreme downhole conditions, while the reactive metallic material enhances strength through chemical reaction with wellbore fluids. After serving its function, the dissolvable portion can be removed by dissolution, eliminating the need for complex drill-through operations required by conventional metal-only constructions.
Solution Approach 2:
The patent utilizes parameter changes by selecting materials whose properties change under specific downhole conditions. The dissolvable material is chosen to remain stable under extreme temperature and pressure during operation but subsequently dissolve when exposed to specific wellbore fluids or chemical environments. This parameter change allows the tool to maintain strength during use while enabling easy removal afterward, resolving the contradiction between durability and ease of removal.
2Strength
If conventional metal components are used, then structural strength is improved, but time and cost for drill-through operations increase
Solution Approach 1:
The patent applies parameter changes by using dissolvable material that transitions from a stable, strength-providing state during operation to a dissolvable state after operation. This material property change eliminates the need for time-consuming drill-through operations required for conventional metal components, as the dissolvable material can be removed by chemical dissolution or natural degradation processes, significantly reducing retrieval time.
Solution Approach 2:
The patent replaces the mechanical drill-through removal process with a chemical dissolution process. Instead of requiring mechanical drilling equipment to cut through metal components, the dissolvable material allows for chemical removal through dissolution in wellbore fluids or exposure to specific chemicals, substituting a time-intensive mechanical operation with a faster chemical process.
3Reliability
If more material is used to ensure durability, then reliability under extreme conditions is improved, but material cost and removal complexity increase
Solution Approach 1:
The patent applies composite materials by creating a layered structure where dissolvable material and reactive metallic material work together to provide the necessary reliability. The dissolvable material provides structural integrity, while the reactive metallic material enhances strength through chemical reaction with wellbore fluids. This composite approach achieves the required reliability with optimized material usage, as the dissolvable portion can be removed after service, reducing waste compared to conventional all-metal constructions that require complete drilling out.
Solution Approach 2:
The patent uses parameter changes by selecting materials that transition from stable to dissolvable states after completing their function. This allows the tool to maintain reliability during operation while enabling selective removal of the dissolvable portion afterward, optimizing material usage and reducing waste compared to conventional materials that require complete removal through drilling.
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 enables faster and more economical wellbore isolation, reduces the time and cost associated with tool removal, and allows for the use of less material, resulting in a more efficient and competitive downhole tool system.
Implementation Method 1
components made of a dissolvable material, any of which may be composite- or metal-based
Implementation Method 2
reactive metallic materials, that can be easily drilled through or dissolve under specific downhole conditions
Data Source
AI summary
A downhole setting system for use in a wellbore, the system having a workstring, a setting tool assembly coupled with the workstring, and a downhole tool coupled with the setting tool assembly in a run-in configuration. In a set configuration the downhole tool is disconnected from the setting tool assembly. At least one component of the downhole tool is made of a dissolvable material