Multilayered Downhole Tool Disintegration via Energetic Core
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Solution Overview
Problem
Existing downhole tools face challenges with uncontrolled disintegration due to corrosion reactions, leading to uncertainties in well operations and potential delays in hydrocarbon production, as they rely on environmental conditions rather than user-defined timelines for disintegration.
Innovation Solution
A multilayered unit comprising a core with energetic materials and an activator, supported by a polymeric or metallic layer, and protected by another layer with a different composition, allowing for controlled disintegration through stress concentration locations and activation by triggers like spark or electrical current, enabling on-demand disintegration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If self-disintegrating downhole tools are used to avoid milling or drilling operations, then disposal time and cost are reduced, but the disintegration period becomes uncontrolled and ruled by well conditions rather than user-defined timelines
Solution Approach 1:
The patent applies preliminary action by pre-encapsulating energetic materials and activators in a multilayered unit that remains stable during deployment and operation. The unit is prepared in advance with all components needed for controlled disintegration, but the actual disintegration reaction is postponed until the predetermined time or condition is reached, allowing users to define the timeline rather than being ruled by well conditions.
Solution Approach 2:
The patent utilizes parameter changes by transforming the disintegration process from a passive corrosion-driven mechanism to an active energy-driven mechanism. By changing the triggering parameter from environmental corrosion rates to a predetermined temporal or conditional parameter, the system achieves reliable control over the disintegration period while maintaining rapid disposal benefits.
2Ease of manufacture
If uncontrolled disintegration occurs due to corrosion reactions, then disposal is achieved without milling or drilling, but operational uncertainties increase and well production may be delayed
Solution Approach 1:
The patent implements feedback by incorporating an activator that responds to a predetermined signal or condition to trigger the disintegration process. This feedback mechanism ensures that disintegration occurs only at the appropriate time, eliminating operational uncertainties and preventing delays in well production while maintaining the simplicity of dissolution-based disposal.
Solution Approach 2:
By pre-configuring the multilayered unit with encapsulated energetic materials and activators, the system prepares for rapid disintegration in advance. This preliminary preparation ensures that when the predetermined time or condition is reached, disintegration occurs immediately and reliably, preventing any delay in well production while maintaining the ease of dissolution-based disposal.
3Reliability
If multilayered units with energetic materials are implemented for controlled disintegration, then disintegration can occur on-demand, but device complexity increases compared to simple corrodible materials
Solution Approach 1:
The patent applies segmentation by dividing the disintegration system into distinct functional layers: an energetic material layer for the disintegration reaction, a support layer for structural integrity, and a protective layer for stability during operation. This segmentation allows each layer to be optimized for its specific function, achieving reliable on-demand disintegration control while keeping the overall structure manageable through clear functional separation.
Solution Approach 2:
The patent utilizes composite materials by combining different materials in a multilayered structure, where each layer is composed of materials specifically selected for its function. This composite approach enables the system to achieve both the reliability of controlled disintegration timing and the simplicity of dissolution-based disposal, as the composite structure integrates multiple functions into a single compact unit.
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 solution enables controlled and rapid disintegration of downhole tools, ensuring timely removal and reducing operational uncertainties, thereby enhancing well production efficiency and planning precision.
Implementation Method 1
a core comprising an energetic material and an activator
Data Source
AI summary
A multilayered unit includes a core comprising an energetic material and an activator; a support layer disposed on the core; and a protective layer disposed on the support layer, wherein the support layer and the protective layer each independently comprises a polymeric material, a metallic material, or a combination comprising at least one of the foregoing, provided that the support layer is compositionally different from the protective layer. The multilayered unit can be embedded in a component, attached to a component, or disposed between two components of a downhole assembly. The downhole assembly containing the multilayered unit has controlled disintegration in a downhole environment.