Quick Development Cell for Shaped Charge Rock Testing
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Solution Overview
Problem
Current standardized testing methods for shaped charges, primarily using concrete targets, are inadequate for predicting perforation flow performance in natural rock formations, leading to suboptimal energy distribution and reduced flow performance in rock targets, and are costly and time-consuming due to the limited number of tests that can be conducted on stressed rock targets.
Innovation Solution
The 'Quick Development Cell' (QDC) facility allows for rapid and efficient testing of shaped charges on stressed rock targets by applying effective stress and minimizing consumables, enabling multiple tests per day, with a focus on optimizing perforation geometry and flow performance, while maintaining standard charge configurations and allowing operation by a single technician.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If shaped charges are optimized for maximum penetration into concrete targets, then penetration capability into concrete is improved, but flow performance in natural rock formations deteriorates
Solution Approach 1:
The patent changes the target material parameter from concrete to stressed natural rock formations, which have different mechanical properties. This parameter change allows the shaped charge design to be optimized for rock penetration characteristics rather than concrete, thereby improving flow performance in actual rock formations while maintaining adequate penetration capability
Solution Approach 2:
The patent uses stressed natural rock formations as test targets that replicate the actual downhole conditions more accurately than concrete targets. By copying the stress state and material properties of natural rock, the testing facility enables optimization of shaped charges for real-world performance rather than idealized concrete penetration
2Measurement precision
If testing is conducted on stressed rock targets to optimize flow performance, then flow performance prediction accuracy is improved, but testing cost and time increase
Solution Approach 1:
The patent segments the rock target into a core sample that can be subjected to controlled stress conditions in a laboratory setting. This segmentation allows the rock core to be tested under specific stress states that simulate downhole conditions, enabling multiple tests with different charge designs without requiring access to actual stressed formations, thereby reducing testing time while maintaining prediction accuracy
Solution Approach 2:
The patent changes the stress state parameter of the rock target to match actual downhole conditions. By applying controlled stress to the rock core samples, the facility can simulate various operating conditions and obtain accurate flow performance data without the need for time-consuming field tests, thereby improving measurement precision while reducing testing time
3Productivity
If multiple tests are conducted on stressed rock targets daily, then development speed is improved, but facility complexity and operational difficulty increase
Solution Approach 1:
The patent designs a universal testing facility that can accommodate multiple types of shaped charge tests on stressed rock cores using a single integrated system. The facility incorporates standardized loading mechanisms, stress application systems, and data collection methods that work across different test configurations, enabling multiple tests daily without proportionally increasing facility complexity
Solution Approach 2:
The patent prepares rock core samples and applies stress conditions in advance before conducting the shaped charge tests. By pre-stressing the rock cores and preparing all test parameters beforehand, the facility enables rapid sequential testing without requiring complex real-time adjustments during each test, thereby improving productivity while managing facility complexity
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 QDC facilitates rapid development and quality control of shaped charges, significantly increasing the number of tests that can be conducted daily, reducing costs, and enabling the creation of optimized designs for improved flow performance in natural rock formations, thereby enhancing well productivity and reducing production expenses.
Implementation Method 1
A shaped charge is an explosive device within which a metal shell called a liner, often conical or hemispherical, is surrounded by a high explosive charge. When the explosive is detonated, the liner is ejected as a very high velocity jet that has great penetrative power.
Implementation Method 2
When the explosive is detonated, the liner is ejected as a very high velocity jet
Implementation Method 3
Perforating systems utilizing shaped explosive charges have become the dominant method for connecting a cased-and-cemented completion to the desired reservoir interval.
Implementation Method 4
the fracture network may extend several feet into the formation. Thus, an enlarged conduit can be created for fluid flow between the formation and the well
Data Source
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AI summary
An improved test setup facility, referred to as a 'Quick Development Cell' (QDC), which allows for rapid turnaround testing with valuable feedback to a design engineer. Because the QDC allows for quick and efficient testing at a sufficient frequency, QDC tests are compatible with production quality control. In addition to fostering improvement of the API's Section 2 type tests using stressed natural rock for benchmark experiments, the QDC tests allow for progress to be made towards the development of a flow-optimized shape charge and superior well performance.