Downhole Propellant Tool for Rapid Casing and Cement Removal
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Solution Overview
Problem
Conventional methods for removing casing and cement in well abandonment operations are slow and costly, as they rely on milling tools or hydro-abrasive cutters, which are inefficient, and perforating charges only produce small holes, failing to address the need for rapid and effective removal of tubulars and associated cement.
Innovation Solution
A tool that uses a propellant source to generate a stream of combustion products, combined with modifying agents, to ablate, cut, displace, heat, abrade, or erode tubulars, allowing for faster and more efficient removal of casing and cement by creating powerful streams of combustion products that can be directed and controlled to manipulate tubulars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If milling tools or hydro-abrasive cutters are used to remove casing and cement, then the removal process can be performed with controlled precision, but the operation becomes very slow and time-consuming
Solution Approach 1:
The patent replaces mechanical milling tools and hydro-abrasive cutters with a propellant charge system that uses controlled explosion to remove casing and cement. The explosive force rapidly fractures and removes material without the slow gradual cutting action of mechanical tools, thereby dramatically increasing removal speed while maintaining sufficient precision for the application.
Solution Approach 2:
The patent changes the fundamental parameter of material removal from gradual mechanical erosion to instantaneous explosive fracture. By using a propellant charge that generates high-pressure gas and shock waves, the system transforms the removal mechanism from low-energy continuous cutting to high-energy discontinuous fracturing, achieving both speed and effectiveness.
2Ease of operation
If conventional mechanical methods are used to remove tubulars, then the process can be controlled and directed, but the operation becomes expensive and time-consuming
Solution Approach 1:
The patent substitutes controlled mechanical removal with controlled explosive removal. The propellant charge system allows operators to direct the explosive force precisely where needed, maintaining ease of operation through controlled placement and ignition, while the explosive mechanism itself dramatically reduces the time required for tubular removal compared to slow mechanical processes.
3Reliability
If perforating charges are used to penetrate casing, then fluid communication can be achieved, but only small holes are produced rather than large holes
Solution Approach 1:
The patent changes the scale and intensity parameters of the explosive charge to transform small perforation holes into large removal cavities. By using a larger propellant charge with greater energy output, the system expands the hole volume significantly while maintaining the reliability of fluid communication, enabling both large hole creation and effective fluid flow.
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 approach significantly reduces the time and cost associated with well abandonment operations by enabling rapid removal of tubulars and cement, allowing for quicker installation of cement plugs and reducing the risk of pressure migration.
Implementation Method 1
upon ignition of the propellant source, the propellant source is adapted to deflagrate, creating at least one stream of combustion products
Implementation Method 2
the propellant source is adapted to deflagrate, creating at least one stream of combustion products
Implementation Method 3
the/each stream of combustion products and/or the modifying agent may erode, ablate, abrade or remove at least a portion of the tubular to be manipulated
Implementation Method 4
the/each stream of combustion products and/or the modifying agent may erode, ablate, abrade or remove at least a portion of the tubular to be manipulated
Implementation Method 5
the/each stream of combustion products and/or the modifying agent may erode, ablate, abrade or remove at least a portion of the tubular to be manipulated
Data Source
AI summary
A tool for manipulating a tubular, such as casing or production tubing, in a downhole environment, includes a housing defining a chamber, the chamber having at least one outlet, a propellant source located within the chamber and an ignition mechanism for igniting the propellant source. Upon ignition of the propellant source, the propellant deflagrates, creating at least one stream of combustion products, the chamber directing the stream of combustion products through the/each outlet, towards the tubular to be manipulated, the/each stream of combustion products combining with at least one modifying agent to manipulate the tubular.