Downhole Tool Controlled Degradation via Chemical Trigger
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Solution Overview
Problem
Current self-disintegrating downhole tools lack control over disintegration time, making it difficult for oil and gas operators to manage the removal of wellbore components, as disintegration is influenced by well conditions and reservoir characteristics, rather than user-defined timelines.
Innovation Solution
A downhole article comprising a matrix material and two chemically isolated substances that react to generate an acid, salt, or heat, allowing for controlled degradation of the matrix material in a downhole fluid, with the option of an explosive device to facilitate contact between the chemicals, ensuring minimal disintegration during service and rapid disintegration when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If self-disintegrating downhole tools are used to eliminate milling or drilling operations, then disposal time and cost are reduced, but control over disintegration timing is lost as it becomes dependent on well conditions and reservoir characteristics
Solution Approach 1:
The patent applies preliminary action by pre-installing trigger mechanisms (such as explosive charges, mechanical actuators, or chemical triggers) within the downhole tool that can be activated at a predetermined time or condition. This allows the disintegration process to be initiated on-demand rather than relying solely on passive corrosion, giving operators control over when disintegration occurs while still using dissolvable materials for the actual breakdown
Solution Approach 2:
The patent utilizes parameter changes by incorporating materials or mechanisms that respond to specific threshold parameters (temperature, pressure, chemical concentration, or time) to initiate disintegration. For example, the tool may remain stable under normal downhole conditions but automatically trigger disintegration when a specific parameter threshold is reached, providing controlled timing based on operational needs rather than unpredictable corrosion rates
2Strength
If dissolvable materials are used for downhole tools to enable self-disintegration, then mechanical properties are maintained during service, but disintegration starts prematurely when well conditions allow corrosion reactions
Solution Approach 1:
The patent applies composite materials by combining dissolvable matrix materials (for controlled disintegration) with non-dissolvable or slow-dissolving structural components (to maintain mechanical integrity during service). This composite structure allows the tool to function reliably with full mechanical properties during the service period while ensuring predictable disintegration when triggered, separating the structural function from the disintegration function
Solution Approach 2:
The patent uses flexible shells or thin film coatings on the dissolvable tool components to protect them from premature corrosion. These protective layers can be designed to degrade slowly or remain intact throughout the service period, preventing early disintegration while allowing the underlying dissolvable materials to maintain their mechanical properties. The protective shell acts as a barrier that controls the timing and rate of corrosion initiation
3Loss of time
If conventional milling or drilling operations are used to remove downhole components, then complete removal is achieved, but the operations are time consuming and expensive
Solution Approach 1:
The patent applies mechanics substitution by replacing the mechanical removal processes (milling or drilling) with a chemical dissolution process. Instead of using mechanical cutting tools to remove the downhole component, the tool is designed to dissolve chemically in the wellbore environment, eliminating the need for complex mechanical disposal operations and significantly reducing both time and cost
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 a controlled disintegration profile, maintaining mechanical properties during tool service while ensuring timely and efficient removal of downhole tools, reducing the need for costly milling or drilling operations.
Implementation Method 1
allowing the first chemical to contact and react with the second chemical generating an acid, a salt, heat, or a combination comprising at least one of the foregoing that accelerates the degradation of the matrix material
Implementation Method 2
these tools can be removed by dissolution of engineering materials using various wellbore fluids
Implementation Method 3
generating an acid, a salt, heat, or a combination comprising at least one of the foregoing that accelerates the degradation
Data Source
AI summary
A method of controllably disintegrating a downhole article comprises disposing the downhole article in a downhole environment, the downhole article containing a matrix material; a first chemical; and a second chemical physically isolated from the first chemical, and allowing the first chemical to contact and react with the second chemical generating an acid, a salt, heat, or a combination comprising at least one of the foregoing that accelerates the degradation of the matrix material in a downhole fluid.