Rounded Explosive Downhole Tool Housing for Wellbore Conveyance
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Solution Overview
Problem
Conventional explosive downhole tools often get stuck in wellbores due to inner diameter restrictions, leading to tool damage and debris issues, which hinder tool conveyance and can obstruct fluid flow and production.
Innovation Solution
The explosive downhole tools are designed with rounded outer surfaces and may be formed of dissolvable materials like magnesium alloys to minimize debris, and are divided into sections for safer handling and compliance with transportation regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional explosive downhole tools with sharp corners are used, then the tool structure is simple and easy to manufacture, but the tool gets stuck on ledges formed by inner diameter restrictions in the wellbore
Solution Approach 1:
The tool housing is designed with a rounded outer surface profile instead of sharp corners and flat surfaces. This curved geometry allows the tool to navigate ledges and inner diameter restrictions in the wellbore without getting stuck, improving conveyance while maintaining structural integrity.
2Productivity
If conventional explosive downhole tools are used, then the tool can perform cutting or expansion functions, but the tool generates debris that obstructs fluid flow and production
Solution Approach 1:
The tool housing material is changed from conventional metals to a dissolvable material that can chemically react and break down after tool deployment. This parameter change in material composition allows the housing to decompose into non-obstructive byproducts, eliminating debris issues while maintaining structural function during operation.
Solution Approach 2:
The tool housing is constructed using composite materials that combine structural integrity during operation with the ability to dissolve or decompose after use. This composite approach allows the housing to serve its mechanical function during deployment while subsequently breaking down to avoid obstructing fluid flow and production.
3Power
If large explosive units are used, then the explosive power is sufficient for cutting or expansion, but the units violate transportation safety regulations
Solution Approach 1:
The explosive charge is divided into multiple smaller explosive units or segments, each containing a limited amount of explosive material that complies with transportation safety regulations. These segmented units are assembled at the wellsite to achieve the total explosive power required for cutting or expansion operations, thereby satisfying both power requirements and transportation compliance.
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 tools can be easily conveyed in and out of wellbores, reducing debris and adhering to safety regulations, thus enhancing operational efficiency and minimizing production delays.
Implementation Method 1
an explosive charge within the housing and comprising a predetermined amount of explosive for at least one of: (i) cutting the wall of the tubular; and (ii) expanding, without puncturing, the wall of the tubular
Implementation Method 2
the explosive downhole tools may have a configuration and/or be formed of a material that minimizes or eliminates debris from the tool in the wellbore after the explosive downhole tool is actuated
Data Source
AI summary
An explosive downhole tool includes a housing having an upper housing part on one side of a window section and a lower housing part on an opposite side of the window section. An explosive charge is provided within the housing for at least one of cutting and expanding the wall of the tubular. The outer surface of at least one of the upper and lower housing part is rounded so as to be devoid of corners. The rounded surface eliminates the presence of sharp corners that may catch on restrictions or protrusions in a wellbore so that the downhole tool is more easily conveyable within a wellbore. Another explosive downhole tool includes fins extending from the housing. The fins have a height that decreases in a direction away from the housing. The shape of the fins enables the downhole tool to be more easily conveyable within the wellbore.