Pyrolytically Degradable Barrier Elements for Stuck Well Tools
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Solution Overview
Problem
Downhole tools used in hydraulic fracturing operations, such as frac plugs and screens, often get stuck and are difficult to retrieve, causing fluid flow blockages and other issues due to their inability to degrade effectively in various well conditions, especially in the presence of oil-based fluids or foams.
Innovation Solution
The use of pyrolytically degradable materials, which break down through thermal decomposition in an inert atmosphere, allowing the well tools to degrade without the need for liquids and maintaining functionality until a target objective is achieved, thereby preventing premature failure and facilitating retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional materials are used for downhole tools, then the tools can maintain structural integrity and functionality during operation, but the tools get stuck and are difficult to retrieve when degradation is needed
Solution Approach 1:
The patent applies parameter changes by using materials whose physical and chemical properties change in response to temperature variations. The downhole tools are made from materials that undergo controlled degradation when exposed to specific temperature ranges, transitioning from a stable, strong state during operation to a degraded, easily retrievable state when needed. This allows the same material to provide both structural integrity during use and ease of retrieval after use.
Solution Approach 2:
The patent implements dynamics by creating a material system that is not static but changes its properties over time and under different conditions. The material dynamically adjusts its characteristics based on temperature exposure, maintaining strength during normal downhole operations but becoming soft and degradable when subjected to controlled heating, enabling easy retrieval without manual intervention.
2Ease of operation
If degradable materials are used to facilitate retrieval, then the tools can break down after use, but they may degrade prematurely in the presence of oil-based fluids or foams
Solution Approach 1:
The patent applies local quality by creating materials with different resistance properties to different substances. The downhole tool materials are designed to be resistant to degradation by oil-based fluids and foams under normal conditions, while remaining susceptible to controlled degradation through temperature activation. This selective responsiveness ensures the material maintains its integrity in the downhole environment but can be deliberately degraded when retrieval is needed.
Solution Approach 2:
The patent uses temperature as an intermediary mechanism to trigger degradation. Rather than direct chemical reactions with fluids that cause premature degradation, the material responds to thermal activation as an intermediate step that initiates controlled breakdown. This intermediary approach allows precise control over when degradation occurs, preventing premature failure while enabling reliable retrieval.
3Reliability
If materials resistant to oil-based fluids are used, then premature degradation is prevented, but the materials may not degrade effectively when retrieval is needed
Solution Approach 1:
The patent applies parameter changes by designing materials that respond to temperature parameter changes. The material maintains resistance to oil-based fluids at downhole temperatures but undergoes controlled degradation when exposed to elevated temperatures during retrieval operations. This parameter-based control allows the material to provide both protection during operation and degradation when needed, resolving the contradiction between resistance and degradability.
4Reliability
If conventional non-degradable materials are used, then the tools maintain functionality throughout operation, but they block fluid flow and cause downhole problems when stuck
Solution Approach 1:
The patent applies discarding and recovering by designing downhole tools that can be deliberately degraded and discarded after completing their function. The materials maintain full functionality and structural integrity during operation but can be activated to degrade when retrieval is desired, converting the tool from a permanent obstacle to a temporary one. This eliminates the harmful effect of stuck tools blocking fluid flow while maintaining operational reliability.
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
The pyrolytically degradable materials ensure that well tools can operate effectively until degradation is triggered by temperature and time, reducing the risk of getting stuck and allowing for controlled breakdown, thus enhancing operational efficiency and ease of retrieval.
Implementation Method 1
A pyrolytically degradable material can include a polymer compound that can degrade by pyrolysis. Degradation by pyrolysis can be the thermal decomposition of materials at elevated temperatures in an inert atmosphere
Data Source
AI summary
A well tool can include a body and at least one barrier element. The barrier element can include a pyrolytically degradable material that is positionable to block a flow of fluid across the body within a wellbore and to degrade by pyrolysis over time within the wellbore.