Perforating Gun Design Optimizing Energy Consumption
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Solution Overview
Problem
Current perforating guns in hydraulic fracturing require high energy consumption due to uneven crack extension caused by heterogeneity in reservoir stresses and physical properties, leading to suboptimal production and increased costs.
Innovation Solution
A system for designing a perforating gun that includes a survey, operation, monitoring, and computing module to optimize perforation parameters by simulating stress-coupled perforation, using Monte Carlo randomization and Newton's method to minimize energy consumption per unit area, balancing perforation hole number and diameter to enhance crack development.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the number of perforation holes is increased to improve crack extension, then the crack area increases, but the energy consumption increases significantly
Solution Approach 1:
The patent applies parameter changes by optimizing the perforation hole diameter and number as key parameters. Through mathematical modeling and iterative calculation, the system determines the optimal combination of perforation parameters (hole diameter, number of holes) that achieves maximum crack area while minimizing energy consumption. This resolves the contradiction by finding the precise parameter values that balance crack extension effectiveness with energy efficiency.
Solution Approach 2:
The patent implements local quality by distributing perforation holes non-uniformly along the perforating gun based on local stress conditions and reservoir properties. The system calculates optimal perforation parameters for different segments of the well, creating locally optimized crack extension patterns that reduce overall energy consumption while maintaining effective crack area. This addresses the heterogeneity of in-situ stresses and reservoir properties mentioned in the background.
2Productivity
If the perforation hole diameter is increased to enhance fluid injection, then the injection rate improves, but the pumping power requirement increases
Solution Approach 1:
The patent uses parameter changes by optimizing the perforation hole diameter as a key variable. The mathematical model evaluates different diameter values to find the optimal size that achieves sufficient injection rate while minimizing the pumping power required. This directly addresses the contradiction between injection rate and pumping power by determining the precise diameter that balances these two parameters.
Solution Approach 2:
The patent employs numerical simulation and mathematical modeling to create a virtual copy of the fracturing process. Through iterative calculation and simulation, the system predicts the relationship between perforation parameters, injection rate, and pumping power without requiring actual field trials. This allows optimization of the diameter parameter to achieve the desired injection rate with minimal power consumption.
3Ease of operation
If traditional perforating gun design is used to maintain simple operation, then the device complexity remains low, but the energy consumption and carbon emissions increase
Solution Approach 1:
The patent applies preliminary action by performing comprehensive mathematical modeling and parameter optimization before the actual fracturing operation. The system calculates optimal perforation parameters in advance based on reservoir characteristics and stress conditions, then uses these pre-determined parameters to guide the perforating gun design and operation. This preliminary optimization reduces energy consumption and carbon emissions while maintaining operational simplicity during the actual fracturing process.
Data Source
AI summary
System for designing a perforating gun capable of reducing energy consumption includes a survey module, an operation module, a monitoring module, a storage module, and a computing module. The operation module is configured to match a target perforating gun to perform a perforating operation to perform an HF operation, obtain a status parameter when the target perforating gun performs the perforating operation and send the status parameter to the monitoring module. The survey module is configured to obtain basic data of a target operation region. The monitoring module is configured to, at a preset frequency, obtain a safety monitoring result by analyzing first data in target data and the status parameter; in response to the safety monitoring result not satisfying a preset safety condition, control a fracturing control pump of the operation module to stop operation; and obtain an HF effect by analyzing second data, in response to the HF effect not satisfying a preset effect condition, update the preset frequency.