Low-Debris Well Perforator with Segmented Charge Design
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Solution Overview
Problem
Conventional perforating systems in oilfield operations generate significant debris during perforation, which can interfere with subsequent perforations, damage equipment, and reduce production by plugging holes and causing fluid loss due to zinc residue from outer charge case vaporization.
Innovation Solution
A low-debris, low-interference well perforator design featuring a semi-solid geometry with disconnected divider segments and a debris guard that decouples charge interaction, providing a tortuous path for shockwaves and containing debris within the perforator, thereby minimizing debris accumulation and interference during detonation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional shaped charges with outer charge case are used, then high-energy perforation is achieved, but significant debris is generated that interferes with subsequent operations
Solution Approach 1:
The invention extracts and removes the outer charge case from the shaped charge design, retaining only the essential explosive charge and liner components. This extraction eliminates the primary source of debris generation while preserving the high-energy perforation capability of the shaped charge jet.
Solution Approach 2:
The invention discards the outer charge case material that would otherwise become harmful debris. By eliminating this component, the system recovers from a high-debris generation mode to a low-debris mode while maintaining perforation effectiveness through the optimized charge and liner design.
2Strength
If zinc outer charge case is used, then structural integrity during detonation is improved, but zinc residue causes fluid loss and requires cleanup operations
Solution Approach 1:
The invention removes the zinc outer charge case from the system, eliminating the source of zinc residue that causes fluid loss. The structural integrity function is replaced by the containment and guidance of the explosive charge and liner without requiring a vaporizing outer case.
Solution Approach 2:
The invention converts the harmful effect of zinc vaporization and residue formation into a benefit by eliminating the zinc outer charge case entirely. This prevents fluid loss and eliminates the need for cleanup operations while maintaining the necessary structural functions through alternative design approaches.
3Volume of moving object
If shaped charges are detonated in close proximity, then efficient use of space is achieved, but interference between charges reduces perforation effectiveness
Solution Approach 1:
The invention segments the explosive charge into discrete charge units with individual liners, allowing each charge to be positioned in close proximity without interference. The segmentation enables efficient space utilization while maintaining the reliability of each individual perforation through controlled charge geometry and spacing.
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 solution effectively reduces debris accumulation and interference between shaped charges, maintaining high-energy perforation performance while minimizing post-perforating solids in the wellbore, ensuring efficient fluid communication and reducing the need for additional cleanup operations.
Implementation Method 1
A series of shaped charges are held in a hollow steel carrier
Implementation Method 2
the shaped charges may be detonated, thereby creating perforations
Implementation Method 3
providing a tortuous path for shockwaves and containing debris within the perforator
Data Source
AI summary
A low-debris low-interference semi-solid well perforator having selectively variable free volume and method for providing such is disclosed according to one or more embodiments. The perforator may include a charge tube holding an independently floating axial stack of selectively variable divider segments, each having one or more concavities formed in upper and lower sides. The segments are arranged so that concavities of adjacent segments form sockets, into which shaped charges are located. The segments provide support to minimize deformation of shaped charge cases yet provide less than 360 degrees circumferential contact about the shaped charges to form selectively variable voids for collecting debris and spall resulting from detonation. The voids and floating segments attenuate detonation shock interference. A debris guard prevents debris from entering the wellbore. Relieving slots in the debris guard attenuates transmission of shock interference through the debris guard.