Controllable Disintegration of Downhole Tools Using Protective Coatings

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Solution Overview

Problem

The challenge in downhole operations is the uncontrolled disintegration of self-disintegrating tools due to corrosion, which affects their mechanical integrity and delays well production, as the disintegration period is not controllable and can cause uncertainties in well operations and planning.

Innovation Solution

A method and assembly for controllably disintegrating downhole articles using a matrix material like Zn, Mg, Al, or their alloys, combined with a device or chemical that facilitates controlled disintegration, such as explosive devices or corrosive materials, activated by signals or timers, ensuring minimal disintegration during service and rapid removal after tool functionality is complete.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If self-disintegrating materials are used in downhole tools, then the tools can be removed by dissolution without milling or drilling operations, but the disintegration process starts uncontrollably as soon as well conditions allow corrosion, causing uncertainty in disintegration timing and tool dimension changes

Engineering Contradiction:

Improvewell production recovery timeVSAvoiddisintegration timing control

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A coating layer is applied to the disintegrable material before the tool is deployed into the wellbore. This preliminary protective action prevents the material from contacting corrosive well fluids during the service period, thereby controlling when disintegration occurs and eliminating timing uncertainty

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coating layer acts as an intermediary barrier between the disintegrable material and the corrosive well environment. It isolates the reactive material from harmful fluids during the service period, allowing controlled removal timing while maintaining material integrity when needed

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If disintegrable material with high mechanical strength is used to ensure tool integrity under high pressure, then the tool can maintain dimensional stability during service, but the material must have minimal initial disintegration which conflicts with the need for rapid disintegration after service

Engineering Contradiction:

Improvetool mechanical strengthVSAvoiddisintegration speed

Core Design Contradiction:

StrengthVSDuration of action of moving object

Solution Approach 1:

The disintegration behavior is controlled by changing the protective state of the material. The coating layer maintains the material in a protected state during service, then its removal or degradation triggers rapid disintegration. This parameter change (from protected to exposed) allows the material to exhibit both high strength and rapid disintegration at different times

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The tool is constructed as a composite structure combining disintegrable matrix material with a non-disintegrating or slowly disintegrating coating layer. This composite approach allows the inner material to provide strength while the outer layer controls the disintegration timing and rate

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

This approach allows for controlled disintegration of downhole tools, maintaining mechanical integrity during service and enabling quicker well recovery by ensuring timely and controlled removal, thus reducing operational delays and uncertainties.

Implementation Method 1

the disintegration process can start as soon as the conditions in the well allow the corrosion reaction of the engineering material to start

Methodology Applied

Scientific EffectCorrosion reaction: Oxidation

Data Source

PatentUS10677008B2Downhole tools and methods of controllably disintegrating the tools

Publication Date: 2020.06.09 BAKER HUGHES CO

AI summary

A method of controllably disintegrating a downhole article comprises disposing a first article in a downhole environment, the first article being the downhole article to be disintegrated; disposing a second article in the downhole environment after the first article is disposed, the second article carrying a device, a chemical, or a combination comprising at least one of the foregoing; and disintegrating the first article with the device, chemical, or the combination comprising at least one of the foregoing from the second article.