Plug-and-Perf Acid Stimulation With Corrosion Inhibitor Protection

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Solution Overview

Problem

Existing hydraulic fracturing processes in the oil and gas industry face challenges in minimizing water waste, reducing equipment time, and optimizing acid diversion during stimulation, particularly due to corrosion issues with stainless steel tools and casing exposed to acidic conditions.

Innovation Solution

A method involving the concurrent use of a corrosion inhibitor composition with mechanical tools, such as a perforating tool and spearhead acid, to minimize corrosion on stainless steel and other alloys, allowing for a one-step plug and perf operation that reduces the need for separate stages and minimizes water usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional multi-stage plug and perf operations are performed without corrosion inhibitors, then mechanical tools can be used for perforation, but corrosion damage occurs to stainless steel tools and casing during acid exposure

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidacid corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A corrosion inhibitor composition is introduced as an intermediary substance between the acid and the metal surfaces (tools and casing). This inhibitor forms a protective film on the metal surfaces, preventing direct contact and chemical reaction between the acid and metal, thereby eliminating corrosion damage while allowing the acid to perform its stimulation function

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The chemical composition of the treatment fluid is modified by adding corrosion inhibitors to change its properties. This parameter change allows the fluid to maintain its acid stimulation capability while simultaneously providing corrosion protection, resolving the contradiction between acid effectiveness and metal protection

Inventive Principle:

Principle #35Parameter changes

2Productivity

If separate stages are used for plug setting and perforation, then mechanical control is maintained, but equipment time and operational complexity increase

Engineering Contradiction:

Improveoperational efficiencyVSAvoidstimulation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The plug setting and perforation operations are merged into a single concurrent operation. The corrosion inhibitor enables this merging by protecting the mechanical tools from acid corrosion during the combined operation, allowing both functions to be performed in one step rather than requiring separate staged operations

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The corrosion inhibitor provides multi-functionality by simultaneously protecting both the plug setting mechanism and the perforation tools from acid corrosion. This universal protection enables a single operational sequence to perform multiple functions that traditionally required separate stages

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If traditional multi-stage operations are performed, then mechanical control and isolation are maintained, but water consumption increases significantly

Engineering Contradiction:

Improveprocess controlVSAvoidwater waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The unnecessary water consumption associated with flushing and cleaning between separate stages is extracted and eliminated from the process. The corrosion inhibitor allows the mechanical tools to remain in place during acid exposure without requiring additional water for protection or cleaning, thereby reducing water waste while maintaining process control

Inventive Principle:

Principle #2Taking out (Extraction)

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 approach significantly reduces stimulation time and water consumption by eliminating a step in the process, saving up to $1,000,000 and 800,000 gallons of water per well, with potential annual industry savings of hundreds of millions of dollars and billions of gallons across North America.

Implementation Method 1

Methodology Applied

Scientific EffectCorrosion inhibition:

Implementation Method 2

allowing the spearhead acid to come into contact with the wireline, perforating tools and perforated area for a predetermined period of time sufficient to prepare the formation for stimulation

Methodology Applied

Scientific EffectAcid dissolution:

Data Source

PatentUS12577453B2Downhole methods and compositions used in such

Publication Date: 2026.03.17 DORF KETAL CHEM FZE

AI summary

A method of the invention prepares a hydrocarbon-bearing formation for stimulation. A bottom hole assembly comprising a plug and a perforation tool connected to a wireline is lowered into the wellbore. Acid is injected into the wellbore such that the acid is in direct contact with the perforation tool, wireline and casing of the wellbore. The plug is positioned downhole beyond a location where a first perforation area is to be made in the casing. The perforation tool is activated creating the first perforation area. The acid then contacts the first perforation area and cementitious debris generated from the casing being perforated. The perforation tool is next moved up-hole to a second location and the casing is again perforated to create a second perforation area. The acid also contacts the second perforated area and cementitious debris generated from the perforated casing. The perforation tool is lastly removed from the wellbore.