Energetic Material Perforating Liner Vaporizes Debris
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Solution Overview
Problem
Perforating systems in oil and gas production generate significant gun fragments during well perforations, which can clog and damage equipment, hindering fluid flow and requiring costly retrieval operations.
Innovation Solution
A perforating assembly with shaped charges comprising a charge case, liner, and energetic materials that disintegrate upon detonation, minimizing debris by vaporizing components and using additives like tungsten, magnesium, and KEVLAR to control the reaction and prevent early initiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shaped charges with metal components are used for perforation, then effective penetration and perforation capability is achieved, but significant gun fragments and debris are generated that clog equipment and damage devices
Solution Approach 1:
The patent changes the physical and chemical parameters of the charge case and liner materials by using energetic materials that undergo phase transitions upon detonation. The charge case comprises an energetic material such as an oxidizer that transitions from solid to vapor phase, fundamentally altering the material state to eliminate fragment generation while maintaining perforation effectiveness.
Solution Approach 2:
The patent exploits phase transitions of energetic materials during detonation. The charge case material (oxidizer) and liner material undergo solid-to-vapor phase transitions, converting solid fragments into gaseous products that dissipate harmlessly. This phase change mechanism eliminates the harmful fragment generation problem while preserving the penetration capability through controlled energy release.
2Force
If high explosive force is used to penetrate casing and formation, then effective perforation is achieved, but components shatter into fragments that restrict fluid flow through chokes and manifolds
Solution Approach 1:
The patent modifies the material parameters of the charge case and liner by using energetic materials with controlled decomposition characteristics. These materials maintain the necessary detonation force for effective perforation while their chemical composition and thermal properties are optimized to vaporize rather than shatter, eliminating fragment generation.
Solution Approach 2:
The patent converts the potentially harmful shattering effect into a beneficial vaporization process. The high detonation force that would normally cause metal components to shatter into damaging fragments is instead harnessed to vaporize the energetic material components, transforming a harmful mechanical fragmentation process into a beneficial phase transition that eliminates debris.
3Strength
If conventional metal components are used in perforating guns, then structural integrity and penetration power are maintained, but hardware retrieval operations are required to remove debris
Solution Approach 1:
The patent employs phase transitions of energetic materials to resolve the contradiction between maintaining structural integrity during perforation and eliminating the need for retrieval operations. The charge case and liner materials transition from solid to vapor phase upon detonation, ensuring structural integrity is maintained during the brief high-stress perforation event while the vaporized remnants are easily dispersed, eliminating retrieval requirements.
Solution Approach 2:
The patent applies the disposable principle by designing the charge case and liner as single-use components made of energetic materials. These components perform their structural function during perforation, then vaporize completely, eliminating the need for expensive retrieval operations. The energetic materials serve their purpose and then disappear, leaving no debris to retrieve.
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
Significantly reduces fragmentation and debris, enhancing fluid flow and eliminating the need for hardware retrieval by vaporizing components post-detonation, thus improving perforation efficiency and reducing operational costs.
Implementation Method 1
The material for the charge case (1) and the liner (5) could comprise a reactive energetic material that changes its state from a solid material to a substantially vapor phase composition.
Implementation Method 2
The reaction of the energetic material (i.e. its change of state) can be induced subsequent to activation of the shaped charge (10).
Implementation Method 3
The effect of the shaped charge detonation produces temperature and pressure changes that in turn initiate the reactive change of state of the material.
Implementation Method 4
The effect of the shaped charge detonation produces temperature and pressure changes that in turn initiate the reactive change of state of the material.
Data Source
AI summary
A perforating system, including a shaped charge assembly comprising a charge case, a liner, and a main body of explosive. The material of the perforating system components, including the gun body, the charge case and the liner may be comprised of an energetic material that conflagrates upon detonation of the shaped charge. The material may be an oxidizer, tungsten, cement particles, rubber compounds, compound fibers, KEVLAR®, steel, steel alloys, zinc, and combinations thereof.