Reusable Charge Dispenser for Consistent Perforation Geometry
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Solution Overview
Problem
Existing perforating systems using shaped charges face challenges in achieving consistent perforation geometry and dimensions due to variations in stand-off distance, jet formation, material interference, casing characteristics, well conditions, and formation heterogeneity, leading to inefficient hydrocarbon flow and environmental concerns.
Innovation Solution
A reusable charge dispenser configured to be carried in a reloadable perforating gun, featuring a body with an internal barrel, projectile chamber, and propellant chamber, along with an ignition system, designed to provide controlled propulsion and ignition for consistent perforation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shaped charges are used for perforation, then hydrocarbon flow is enhanced, but perforation geometry consistency deteriorates due to stand-off distance variations
Solution Approach 1:
A reusable barrel is introduced as an intermediary component between the shaped charge and the casing. The barrel is positioned within the perforating gun and serves as a guide and constraint for the shaped charge during firing, ensuring consistent stand-off distance and perforation geometry while allowing the shaped charge to maintain its high-velocity jet for effective hydrocarbon flow enhancement.
2Productivity
If shaped charges are used for perforation, then reservoir access is improved, but hole shape uniformity deteriorates due to jet formation variations
Solution Approach 1:
The reusable barrel acts as a mediator that stabilizes the jet formation process. By providing a consistent internal geometry and positioning the shaped charge at a fixed stand-off distance, the barrel ensures that the high-velocity jet maintains uniform shape and penetration characteristics, resulting in consistent hole shapes that improve reservoir access without compromising hole uniformity.
3Reliability
If conventional perforating guns are used, then perforation is achieved, but material interference affects jet integrity
Solution Approach 1:
The reusable barrel serves as a controlled intermediary structure that protects the jet from harmful interactions with the carrier material. The barrel's design allows the shaped charge jet to form and penetrate through the barrel wall in a controlled manner, maintaining jet integrity and preventing deformation or fragmentation that would occur with direct contact between the jet and the carrier.
4Reliability
If single-use perforating guns are used, then perforation is achieved, but waste increases and environmental impact worsens
Solution Approach 1:
The invention implements a reusable barrel system that can be recovered and reused across multiple perforation operations. After the shaped charge completes its function, the barrel remains intact and can be retrieved from the wellbore for subsequent use, significantly reducing waste compared to single-use perforating guns while maintaining perforation effectiveness.
Solution Approach 2:
The reusable barrel enables continuous useful action by allowing multiple firing cycles with the same barrel. The barrel can be reloaded with fresh shaped charges and reused for subsequent perforation operations, eliminating the need to discard and replace the entire perforating gun after each use, thereby reducing material waste and environmental impact.
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 solution enables consistent and uniform perforations, reducing waste and environmental impact by allowing multiple uses of the charge dispenser, improving hydrocarbon flow efficiency, and enhancing safety through controlled combustion processes.
Implementation Method 1
a propellant chamber for housing and containing the propellant
Implementation Method 2
A shaped charge included an explosive charge encased in a metal liner that, upon detonation, transformed into a high-velocity jet with exceptional penetration capabilities
Data Source
AI summary
One example device, usable in a downhole process, includes a body configured to be removably received in a corresponding recess of a perforation gun, a propellant chamber defined in the body, a projectile chamber defined in the body and positioned in the body above, and in communication with, the propellant chamber, a barrel defined in the body and positioned in the body above, and in communication with, the projectile chamber, and a muzzle defined in the body and positioned in the body above, and in communication with, the barrel.