Reactive Shaped Charges for Sand Control in Perforation
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Solution Overview
Problem
In poorly consolidated formations, sand production during hydrocarbon extraction leads to equipment damage and reduced well performance due to ineffective sand control methods, including erosion of mechanical filters and uneven gravel packing, necessitating additional cleanup activities and risking equipment failure.
Innovation Solution
The use of reactive shaped charges to perforate the well casing, which reduces sand production by increasing the diameter of perforation tunnels and distributing debris uniformly, thereby minimizing flux rates and eliminating the need for secondary cleanup activities and sand control filters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional shaped charges are used to perforate the casing, then a large number of holes can be created simultaneously at low cost, but the perforation tunnels are small in diameter and create high flux rates that lead to sand production
Solution Approach 1:
The patent changes the key parameter of perforation tunnel diameter by using reactive shaped charges that create larger tunnels. This parameter change reduces the flux rate (flow per unit area) through each tunnel, thereby reducing sand production while maintaining high productivity through multiple perforations
Solution Approach 2:
The reactive material in the shaped charge performs preliminary action by reacting with formation materials during perforation to enlarge the tunnel diameter before production begins. This preliminary enlargement prevents high flux rates and sand production from occurring during subsequent hydrocarbon extraction
2Reliability
If sand screens are installed to filter sand particles, then sand entry into the wellbore is prevented, but the mechanical filters are vulnerable to erosion from high velocity fluid ingress
Solution Approach 1:
The patent extracts or eliminates the need for mechanical sand screens by creating sufficiently large perforation tunnels that naturally accommodate sand particles without requiring filtration. The large tunnel diameter allows sand to be carried along with fluids without plugging or eroding mechanical filters
Solution Approach 2:
The patent converts the harmful effect of sand production into a benefit by using the reactive shaped charge to create such large perforation tunnels that sand particles can flow freely through them without causing erosion or plugging. The sand that would normally be harmful is now effectively co-produced without damaging the wellbore
3Reliability
If gravel packing is performed to control sand production, then sand influx is limited, but uneven packing creates voids that lead to filter erosion and premature failure
Solution Approach 1:
The patent eliminates the need for gravel packing by creating perforation tunnels large enough to naturally handle sand production without requiring an artificial gravel filter. This removes the source of uneven packing and void formation entirely
Solution Approach 2:
Instead of using small perforations and adding gravel to filter sand (traditional approach), the patent inverts the approach by creating large perforations that naturally accommodate sand flow without filtration. This reversal eliminates the need for gravel packing and its associated uniformity problems
4Ease of operation
If the number of open perforations is maximized to reduce erosion risk, then more inflow points are available, but debris blocks tunnels increasing the risk of sand production
Solution Approach 1:
The patent changes the parameter of tunnel diameter to be sufficiently large that debris does not block the perforations. This allows maximization of open perforations for better inflow distribution while the large diameter prevents debris plugging, thereby reducing sand production risk
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 method enhances sand control completion longevity, reduces sand production, and allows for higher productivity with reduced risk of equipment failure by creating a larger flow area and uniform inflow distribution across the wellbore, enabling efficient hydrocarbon extraction without additional equipment or cleanup steps.
Implementation Method 1
activating the charge carrier creates a first explosive event that forms a plurality of perforation tunnels within the adjacent failure-prone formation
Implementation Method 2
the liner material or contents reacts with the formation material or injected carrier fluid to create a second, local explosive event within each perforation tunnel
Implementation Method 3
the liner material or contents reacts with the formation material or injected carrier fluid
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
By using reactive shaped charges to perforate failure prone formations, the present invention is able to keep formation sand in place and increase productivity. An efficient flow distribution is surprisingly produced without requiring surge flow or post-perforation stimulation. Further, using the secondary reactive effects of reactive shaped charges allows for the reduction of the risk of erosion and minimization of sand production. In a preferred embodiment, a liner capable of producing a strongly exothermic intermetallie reaction between liner components within and around the tunnel is used to achieve a high percentage of substantially clean and enlarged perforation tunnels conducive to flow or gravel packing.