Phased Perforating Gun Shaped Charge Orientation
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Solution Overview
Problem
Current perforation systems in the oil and gas industry fail to minimize multiple fracture initiations, efficiently reduce tortuosity and energy loss, and achieve optimal wellbore production efficiency by not allowing shaped charges to intersect at a preferred fracturing plane, leading to reduced oil and gas flow rates due to tortuous flow paths and ineffective fracture planes.
Innovation Solution
A perforating gun system with shaped charge clusters that are angled and spaced to intersect at a preferred fracturing plane, initiating fractures at the location of least principal stress, thereby reducing tortuosity and increasing fracture length, using a support strip and cylindrical barrel design to secure and orient charges for precise intersection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If shaped charges are shot at 60°, 90°, or 120° phasing to create multiple fracture planes, then more fracture planes are created, but near wellbore friction increases and fracturing treatment placement becomes difficult
Solution Approach 1:
The patent applies local quality by creating charged clusters with specific angular orientations (upward and downward charges at different angles) to generate perforations that converge at a preferred fracturing plane. This localized angular variation ensures that fracture initiation occurs at the least principal stress location, creating optimal fracture planes while avoiding multiple ineffective fracture planes that cause high near wellbore friction.
Solution Approach 2:
The patent employs asymmetry by using an asymmetric charge configuration where upward and downward shaped charges are positioned at different angular orientations relative to the wellbore axis. This asymmetric arrangement creates non-symmetric perforation paths that converge at a specific preferred fracturing plane, ensuring optimal fracture propagation direction while avoiding the creation of multiple fracture planes that lead to high friction losses.
2Productivity
If multiple perforation holes are shot to increase fracture initiation sites, then more fracture planes are created, but energy and pressure loss increase due to tortuosity
Solution Approach 1:
The patent merges multiple charged clusters into a coordinated system where upward and downward charges are strategically positioned to create perforations that converge at a common preferred fracturing plane. This merging approach ensures that multiple fracture initiation sites are created, but all fractures propagate in the same optimal direction, minimizing tortuosity and energy loss while maximizing fracture length and productivity.
Solution Approach 2:
The patent applies preliminary action by pre-positioning shaped charges at specific angular orientations before firing, so that the perforations are already configured to converge at the preferred fracturing plane. This preliminary angular arrangement ensures that when fractures initiate, they do so at the location of least principal stress and propagate in the optimal direction, avoiding energy loss from tortuous paths.
3Productivity
If perforations are aligned with preferred fracture planes, then tortuosity is reduced and flow efficiency increases, but the system complexity increases due to precise angle requirements
Solution Approach 1:
The patent segments the charge system into distinct upward and downward charged clusters, each with specific angular orientations. This segmentation allows for simplified design and manufacturing of individual charge modules while maintaining the overall complexity of the angular orientation system. Each segment can be independently manufactured and assembled, reducing the complexity of precision angle requirements.
Solution Approach 2:
The patent incorporates a swivel mechanism that allows the charged clusters to be dynamically oriented at the required angles during deployment. This dynamic orientation capability simplifies the overall system design by allowing charges to be positioned at precise angles without requiring complex fixed-angle manufacturing, thereby reducing device complexity while maintaining high flow efficiency.
4Length of stationary object
If more fracture length is achieved, then oil and gas flow increases, but the number of perforations required increases, leading to higher friction
Solution Approach 1:
The patent changes the angular parameters of the shaped charges to optimize fracture propagation. By adjusting the angular orientation of upward and downward charges, the system achieves longer fracture lengths with fewer perforations. This parameter optimization ensures that fractures propagate in the optimal direction with minimal tortuosity, reducing the total number of perforations needed and thereby lowering friction losses.
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 system enhances oil and gas flow rates by creating minimal tortuosity paths and longer fracture extensions, increasing the efficiency of fracturing treatments and maximizing production by focusing energy on the preferred fracturing plane.
Implementation Method 1
These charges are loaded in a perforation gun and are typically shaped charges that produce an explosive formed penetrating jet in a chosen direction
Implementation Method 2
Fractures will initiate and propagate in the preferred fracture plane of the formation
Data Source
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AI summary
A limited entry perforating phased gun system and method for accurate perforation in a deviated/horizontal wellbore is disclosed. The system/method includes a gun string assembly (GSA) deployed in a wellbore with shaped charge clusters. The charges are spaced and angled such that, when perforated, they intersect at a preferred fracturing plane. Upon fracturing, the fractures initiate at least principal stress location in a preferred fracturing plane perpendicular to the wellbore from an upward and downward location of the wellbore. Thereafter, the fractures connect radially about the wellbore in the preferred fracturing plane. The fracture treatment in the preferred fracturing plane creates minimal tortuosity paths for longer extension of fractures that enables efficient oil and gas flow rates during production.