Expendable Hollow Carrier Direct Coupling for Shorter Perforating Guns

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Solution Overview

Problem

Existing perforating systems for wellbores face challenges in machining and forming components due to pressure-containing requirements, leading to increased weight, length, and cost, as well as potential fluid leak paths and inefficiencies in coupling perforating guns without sufficient wall thickness for direct coupling.

Innovation Solution

The use of an expendable hollow carrier (EHC) formed through deep drawing and machining processes, allowing direct coupling of perforating guns without intermediate components, reducing weight, length, and cost, while minimizing fluid ingress and leak paths by forming integral coupling components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional machining and forming processes are used to create pressure-containing components, then the components can withstand wellbore pressures, but the wall thickness thresholds make machining and forming challenging and increase device complexity

Engineering Contradiction:

Improvepressure-containing capabilityVSAvoidmachining and forming complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs an expendable hollow carrier (EHC) that is discarded after a single use. The EHC is formed through deep drawing rather than traditional machining, avoiding the complexity of creating pressure-containing components with sufficient wall thickness for coupling. After deployment, the EHC is expended, eliminating the need for complex, reusable pressure-containing structures with thick walls.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of operation

If intermediate coupling components (tandem subs) are used to connect perforating guns, then coupling can be achieved, but the string weight and length increase

Engineering Contradiction:

Improvecoupling capabilityVSAvoidperforating string weight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent integrates the coupling functionality directly into the expendable hollow carrier itself. The EHC includes coupling components formed as part of its structure, allowing direct coupling between carriers without requiring separate intermediate coupling components like tandem subs. This merging of functions reduces the overall weight and length of the perforating string.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If intermediate coupling components are used to connect perforating guns, then coupling can be achieved, but the string length increases and fluid leak paths are created

Engineering Contradiction:

Improvecoupling capabilityVSAvoidperforating string length

Core Design Contradiction:

Ease of operationVSLength of moving object

Solution Approach 1:

The coupling components are integrated directly into the expendable hollow carrier structure, eliminating the need for separate intermediate coupling components. This direct integration reduces the overall length of the perforating string by removing the additional length contributed by tandem subs and other intermediate components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The expendable nature of the EHC allows for a simpler, more direct coupling design that prioritizes reducing leak paths over reusability. The single-use characteristic permits a more streamlined structure with fewer interfaces where fluid leaks could occur, as the carrier is discarded after one deployment rather than being reused multiple times.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If traditional pressure-containing components are used, then hydraulic isolation can be maintained, but the cost and complexity increase

Engineering Contradiction:

Improvehydraulic isolation integrityVSAvoidcomponent structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The expendable hollow carrier provides hydraulic isolation for its single use period through its simple drawn structure, eliminating the need for complex, reusable pressure-containing components. The EHC is designed to fulfill the hydraulic isolation requirement for one deployment and then is discarded, avoiding the complexity of creating durable, reusable pressure-containing structures.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 results in a lighter, shorter, and cheaper perforating string with reduced fluid leak paths and improved reliability by eliminating the need for tandem subs, enhancing the efficiency and cost-effectiveness of perforating operations.

Implementation Method 1

forming an expendable hollow carrier (EHC) via a drawing process

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS11267031B2Expendable hollow carrier fabrication system and method

Publication Date: 2022.03.08 BAKER HUGHES CO

AI summary

Embodiments of the present disclosure include a method for fabricating a perforating gun including forming an expendable hollow carrier (EHC) via a drawing process. The method also includes determining a wall thickness of the EHC is above a threshold. The method includes machining a coupling component to at least one end of the EHC. The method further includes installing perforating components within an interior of the EHC.