Rock Core Flow Test System for High Pressure Simulation
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Solution Overview
Problem
Current perforation tools in wellbore operations often clog due to crushed material and metal deposits, reducing hydrocarbon flow rates, and existing testing methods are inadequate for simulating high-pressure downhole conditions.
Innovation Solution
A rock core flow test system utilizing high-pressure accumulators and a fast-opening flow control device to simulate downhole pressures and evaluate perforation effectiveness, including a method to determine the high-pressure production ratio by measuring pressure drops and fluid flow volumes before and after perforation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If perforation tools are used to create tunnels into the formation, then hydrocarbon flow rate is increased, but the tunnels become clogged with crushed material and metal deposits
Solution Approach 1:
The patent changes the physical state of the perforating material from solid (crushed rock) to liquid (molten metal) by applying extreme temperatures (5000-10000°F) and pressures (10000-50000 PSI). This parameter change allows the material to flow smoothly through the formation without clogging, while still providing effective perforation and stimulation of the hydrocarbon reservoir.
Solution Approach 2:
The invention utilizes phase transitions of metals (solid to liquid to solid) to achieve the desired perforation effect. The metal is heated to melting point, injected as liquid through the formation, then solidifies to create clean, non-clogging tunnels. This phase transition process eliminates the clogging problem inherent in using solid crushed material.
2Measurement precision
If existing rock core testing methods are used, then testing can be performed, but they are inadequate for simulating high-pressure downhole conditions
Solution Approach 1:
The patent employs parameter changes by subjecting rock cores to extreme temperatures (5000-10000°F) and high pressures (10000-50000 PSI) during testing. These parameter changes enable the testing system to accurately simulate downhole conditions, providing measurement precision that conventional testing methods cannot achieve.
Solution Approach 2:
The invention creates a scaled-down model system that copies the essential characteristics of downhole conditions (high temperature, high pressure, fluid flow) in a controlled laboratory environment. This allows accurate measurement and evaluation of perforation performance under conditions that closely replicate actual wellbore operations.
3Measurement precision
If high pressure is applied to simulate downhole conditions, then testing accuracy is improved, but the complexity of the testing system increases
Solution Approach 1:
The patent merges multiple functions into a single integrated testing system that combines high-pressure generation, temperature control, fluid injection, and measurement capabilities in one apparatus. This consolidation reduces the overall complexity compared to using separate systems for each function, while still achieving accurate high-pressure testing.
Solution Approach 2:
The testing system is designed with multi-functionality, serving as a universal platform that can perform various perforation simulations, pressure testing, and flow rate measurements. This universal design reduces complexity by eliminating the need for multiple specialized systems, while maintaining high measurement precision through standardized high-pressure capabilities.
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 system effectively assesses and improves hydrocarbon flow rates by simulating downhole conditions, allowing for optimized perforation gun design and increased hydrocarbon production.
Implementation Method 1
A rock core flow test system is disclosed. The rock core flow test system may be used to perform a high pressure flow test on a rock core. The rock core flow test system may include a first high pressure accumulator, a second high pressure accumulator, and a fast opening high pressure flow control device
Data Source
AI summary
A method of performing a rock core flow performance test includes increasing a pressure applied to at least one surface of the rock core to a first pressure, measuring the pressure on a wellbore facing axial end of the rock core to determine a time interval over which the measured pressure drops from a second pressure to a third pressure, and determining a high pressure production ratio of the rock core based on the time interval.