Mechanical Perforator for Subterranean Formation

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Solution Overview

Problem

Existing perforation methods using explosives dissipate a substantial portion of energy and create debris, which can plug the newly formed flow tunnel, and are prohibited or undesirable in certain jurisdictions, necessitating an alternative for establishing fluid communication between tubular strings and the surrounding annulus.

Innovation Solution

A downhole mechanical perforator assembly with a radially outwardly extendable penetrator, driven by a mandrel, creates perforations in the tubular string without explosives, utilizing a retractable mechanism to ensure efficient fluid flow and minimize debris, suitable for various well configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If explosive perforating devices are used to create openings through the tubular string, then fluid communication between the tubular string and annulus is established, but a substantial portion of energy is dissipated and debris is created that can plug the flow tunnel

Engineering Contradiction:

Improvefluid communication establishmentVSAvoidenergy dissipation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent replaces the explosive mechanical system with a mechanical punch system. The punch member is driven axially to radially outwardly extend through the tubular string wall, creating a perforation through pure mechanical force rather than chemical explosion. This substitution eliminates energy dissipation associated with explosive reactions and prevents debris generation that would plug flow tunnels.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the explosive component from the perforating system. By removing the high explosive and shaped charge liner, the system avoids the harmful effects of explosive energy dissipation and plasma jet debris, achieving clean perforation through mechanical means alone.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If explosive perforating devices are used, then openings are created through the tubular string, but high-energy plasma creates debris that plugs the newly created flow tunnel

Engineering Contradiction:

Improveflow path creationVSAvoiddebris generation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes the explosive plasma-based mechanism with a direct mechanical punching mechanism. The punch member physically displaces material to create the perforation without generating high-energy plasma, thereby eliminating debris that would otherwise plug the flow tunnel.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful explosive energy into a beneficial concentrated mechanical force. Instead of allowing energy to dissipate as harmful plasma and debris, the force is concentrated in the punch member to efficiently create a clean perforation path.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If explosive perforating devices are used, then perforations are created, but certain jurisdictions prohibit or discourage their use

Engineering Contradiction:

Improveperforation capabilityVSAvoidjurisdictional compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the chemically-based explosive system with a mechanically-based punching system. This substitution removes the regulatory and environmental concerns associated with explosives, making the perforating method compatible with jurisdictions that prohibit or discourage their use while maintaining full perforation capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Loss of energy

If a radially outwardly extendable penetrator is used to create perforations, then energy dissipation is reduced, but the device complexity increases due to the retractable mechanism

Engineering Contradiction:

Improveenergy efficiencyVSAvoidmechanism complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent employs dynamic elements including the radially outwardly extendable punch member and retractable mechanism. These dynamic components allow the system to transition between a compact configuration for deployment and an extended configuration for perforation, managing the trade-off between complexity and energy efficiency.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses a nested structure where the punch member is contained within the perforator assembly and can be radially extended as needed. The retractable mechanism allows components to be nested during transport and deployment, then extended for operation, reducing overall system complexity while maintaining energy efficiency.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS10208572B2Apparatus and method for perforating a subterranean formation

Publication Date: 2019.02.19 HALLIBURTON ENERGY SERVICES INC

AI summary

Method and apparatus are presented for perforating a subterranean formation so as to establish fluid communication between the formation and a wellbore by perforating a tubular with a mechanical perforator. The mechanical perforator comprises a perforator housing, a mandrel slidably positioned within the perforator housing, and at least one penetrator outwardly extendable from the perforator housing. When shifted axially the mandrel causes at least a portion of the at least one penetrator to extend outwardly from the perforator housing to perforate the tubular.