Shaped Charge Assembly System Segmentation
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Solution Overview
Problem
The handling and transportation of conventional shaped charges for well perforation are hazardous and costly due to the need for specialized packaging and regulatory compliance, which increases the risk of detonation and delays in oilfield operations.
Innovation Solution
A system using pre-manufactured explosive pellets of universal morphology and composition, combined with variable dimension liners for on-site assembly into shaped charges, reducing hazards and regulatory burdens by separating the explosive components from the liners during transport and allowing for tailored performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shaped charges are individually assembled with liners and explosive pellets before transport, then the perforation performance is optimized, but the transportation hazards and regulatory compliance burden increase dramatically
Solution Approach 1:
The shaped charge is divided into separate components: explosive pellets, casings, and liners. These components are transported separately and assembled at the wellsite, reducing transportation hazards while maintaining perforation performance. The liner and explosive pellet are kept separate during transport and only combined when needed for the actual perforation operation.
Solution Approach 2:
The explosive pellets are pre-manufactured with universal morphology and composition, and the liners are prepared separately with variable dimensions. Both components are readied in advance but kept separate, allowing for safe transport and subsequent assembly at the wellsite when needed.
2Reliability
If specialized packaging and thick barrier structures are used for each shaped charge, then safety during transport is improved, but the cost and device complexity increase
Solution Approach 1:
By segmenting the shaped charge into separate components (explosive pellets, casings, liners) that are transported separately, the need for complex specialized packaging for each complete shaped charge is eliminated. Simple containers can be used for each component type, reducing overall packaging complexity and cost.
Solution Approach 2:
The explosive pellets are designed with universal morphology and composition, allowing them to be used with different liners for various perforation applications. This universality simplifies packaging and transport requirements, as the same explosive pellet design can serve multiple functions when combined with different liners.
3Productivity
If conventional shaped charges are transported in bulk, then the shipping efficiency is improved, but the regulatory compliance time and expense increase
Solution Approach 1:
The shaped charge components are transported separately in bulk (explosive pellets in one container, liners in another), which maintains shipping efficiency while significantly reducing regulatory compliance requirements. The separation of components means they are not classified as complete explosive devices during transport, reducing inspection and paperwork requirements.
Solution Approach 2:
The liner is extracted from the complete shaped charge assembly during transport. By removing the liner component, the remaining explosive pellet and casing assembly has reduced regulatory restrictions, allowing for more efficient bulk shipping while the liner is added at the wellsite when needed.
4Adaptability or versatility
If multiple different sized and shaped carriers are used for different shaped charge types, then the tailored performance is achieved, but the handling complexity and cost increase
Solution Approach 1:
The shaped charge system is segmented into standardized explosive pellets and variable liners. The explosive pellets use a universal design that simplifies handling, while the liners provide the performance tailoring. This segmentation allows all pellets to be handled the same way regardless of the specific application.
Solution Approach 2:
The explosive pellets are designed with universal morphology and composition that can work with multiple different liner types and dimensions. This universality eliminates the need for multiple specialized carriers, as a single standardized container can hold all explosive pellets regardless of which specific liner will be used with them.
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 approach minimizes transportation hazards and regulatory compliance issues while enabling on-site assembly of tailored shaped charges, reducing costs and delays associated with handling and shipping conventional shaped charges.
Implementation Method 1
an explosive pellet of compressed material is provided in a casing and may be individually loaded into the gun as a shaped charge. Thus, once detonated, each shaped charge may perform similar to a ballistic jet in forming an adjacent perforation.
Implementation Method 2
this manner of operation is enhanced by a liner that is placed over the explosive pellet. That is, the pellet is secured within the cavity of a casing and provided with a liner thereover so as to enhance and tailor the performance of the fully assembled shaped charge.
Data Source
AI summary
A system where a group of substantially universal pre-manufactured explosive pellet assemblies are provided for on-site forming of shaped charges. That is, a specifically tailored liner may also be separately provided to the worksite/oilfield and combined with any one of the pellet assemblies so as to form a shaped charge having characteristics that are determined by the particular liner used. In this manner, hazardous shipping of fully assembled shaped charges may be avoided while at the same time allowing the operator a full range of shaped charge performance options based on the availability of uniquely tailored performance determinative liners that are also provided to the oilfield location.