Faceted Rupture Disc Structure for Controlled Wellbore Fragmentation
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Solution Overview
Problem
Conventional rupture discs used in wellbore fluid isolation create large, sharp fragments during rupture, causing blockages and difficulties in removal due to their smooth arched surfaces, which are not designed to fracture into smaller, manageable pieces.
Innovation Solution
A rupture disc with a central portion featuring a plurality of facets defined by seams, configured to fracture along these weak points, producing smaller fragments that are easier to clear, and designed to withstand specific pressure ratings or mechanical forces, with optional fluid dissolution for material breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rupture discs with smooth arched surfaces are used, then high pressure resistance is achieved, but large sharp fragments are created during rupture causing blockages and removal difficulties
Solution Approach 1:
The rupture disc is designed with pre-formed seams that segment the disc into multiple smaller sections. When the disc ruptures under pressure, these pre-defined seams guide the fragmentation process, dividing the disc into smaller, more manageable pieces rather than large sharp fragments. This segmentation principle directly addresses the harmful effect of large fragments while maintaining the structural integrity needed for pressure resistance.
Solution Approach 2:
The rupture disc features different surface characteristics in different regions: the central portion has a smooth arched surface for withstanding pressure, while the periphery includes facets and seams designed for controlled fragmentation. This local differentiation allows the disc to simultaneously achieve high pressure resistance in the central area and controlled fragmentation into smaller pieces at the periphery during rupture.
2Reliability
If smooth arched surfaces are used on rupture discs, then pressure containment capability is improved, but fragment removal from wellbore becomes difficult
Solution Approach 1:
By incorporating pre-formed seams that divide the disc into smaller segments, the invention makes fragment removal significantly easier. The smaller fragmented pieces can be more easily retrieved from the wellbore compared to large monolithic fragments, directly improving ease of operation while the central smooth arched portion maintains pressure containment reliability.
Solution Approach 2:
The design applies different surface qualities to different regions: the central smooth arched surface maintains pressure containment, while the peripheral faceted regions with seams facilitate easier fragmentation and removal. This local quality differentiation resolves the contradiction between maintaining reliable pressure containment and enabling easy fragment removal.
3Reliability
If conventional rupture disc design is used, then fluid sealing is achieved, but disc fragments block openings after rupture
Solution Approach 1:
The pre-formed seams segment the rupture disc into smaller pieces that are less likely to block openings compared to large fragments from conventional discs. The segmentation ensures that even after rupture, the fragments remain small enough to pass through or be removed from wellbore openings without causing blockages, while the intact disc maintains fluid sealing during operation.
Solution Approach 2:
The invention applies local quality by maintaining a smooth central surface for effective fluid sealing during operation, while incorporating peripheral facets and seams that control fragmentation into small non-blocking pieces. This regional differentiation allows the disc to simultaneously achieve reliable fluid sealing and prevent blockage formation after rupture.
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
The rupture disc effectively fractures into a larger number of smaller fragments, facilitating easier removal and reducing the risk of blockages, while maintaining high pressure resistance and fluid sealing capabilities.
Implementation Method 1
The central portion is configured to fracture along the plurality of seams in response to a rupture event
Implementation Method 2
allowing a first predefined pressure on the outer surface and a second predefined pressure on the inner surface
Data Source
AI summary
A rupture disc configured to fluidly seal a passageway. The rupture disc includes a base extending from a distal surface to a proximal end, and a central portion extending across the proximal end of the base. The central portion traverses a central axis defined by the base. At least one surface of the central portion, such as an outer surface or inner surface, includes a plurality of facets defined by a plurality of seams. The facets may include one or more flat surfaces and/or one or more conical surfaces. A rupture disc system for fluidly sealing a portion of a wellbore includes the rupture disc disposed within and extending across a housing central bore of a housing, with one or more sealing members engaging the rupture disc and an inner surface of the housing central bore to fluidly seal the housing central bore.