Linear Shaped Charge Tool for Cemented Casing Removal
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Solution Overview
Problem
Conventional methods for removing cemented casing in oil and gas wells are slow and expensive due to the use of milling tools or hydro-abrasive cutters, which are inefficient in cutting through metallic casing and associated cement.
Innovation Solution
A tool comprising linear shaped charges supported by a carrier and a detonation mechanism that projects material outwardly upon detonation, creating penetrations and fractures in the casing and cement, allowing for efficient fragmentation and removal of tubular sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If milling tools or hydro-abrasive cutters are used to remove cemented casing, then the casing can be removed, but the process is slow and expensive
Solution Approach 1:
The patent replaces conventional mechanical cutting methods (milling tools, hydro-abrasive cutters) with a shaped charge system that uses controlled explosive detonation to fragment and remove cemented casing. This substitution of mechanical systems with chemical energy release achieves rapid penetration and removal without the time-consuming gradual cutting process
Solution Approach 2:
The invention changes the physical state and energy parameters by using high-explosive shaped charges that concentrate energy into a focused jet upon detonation. This parameter change from distributed mechanical force to concentrated explosive energy enables instantaneous penetration through cemented casing, dramatically improving productivity and reducing operational time
2Ease of manufacture
If conventional cutting methods are used, then casing removal is achieved, but the process is expensive
Solution Approach 1:
By replacing expensive, time-consuming mechanical cutting equipment with relatively simple shaped charge assemblies, the invention achieves cost-effective casing removal. The shaped charge system requires minimal equipment infrastructure compared to milling or hydro-abrasive systems, reducing operational costs while maintaining high removal efficiency
Solution Approach 2:
The shaped charges are designed as disposable, single-use elements that are deployed, detonated, and discarded. This eliminates the need for expensive, maintenance-intensive mechanical cutting tools and equipment, making the overall process more cost-effective while achieving rapid casing removal
3Productivity
If linear shaped charge is detonated to penetrate tubular, then rapid fragmentation is achieved, but the tool complexity increases
Solution Approach 1:
The shaped charge system is segmented into modular components (charge assembly, carrier, detonation mechanism) that can be independently designed, manufactured, and deployed. This segmentation simplifies the overall tool structure while enabling rapid fragmentation through coordinated detonation of multiple charge segments along the tubular
Solution Approach 2:
A simple carrier or support structure serves as an intermediary to hold and position the linear shaped charge against the tubular surface. This intermediary component bridges the gap between the explosive charge and the target, enabling effective energy transfer without requiring complex tooling or attachment mechanisms
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 tool enables rapid and cost-effective penetration and fragmentation of tubulars, facilitating easier removal and reducing operational time by creating lines of weakness and shockwaves that fracture the casing and cement, allowing for efficient abandonment of wells.
Implementation Method 1
at least one length of linear shaped charge
Implementation Method 2
at least one detonation mechanism for detonating the/each length of linear shaped charge
Implementation Method 3
which is thereby penetrated; wherein the at least one length of linear shaped charge is arranged such that, upon detonation, the trajectory of at least one portion of the projected material intersects the trajectory of at least one other portion of projected material
Data Source
AI summary
A tool for penetrating a tubular as described. The tool comprises at least one length of linear shaped charge, a carrier adapted to support the/each length of linear shaped charge, and at least one detonation mechanism for detonating the/each length of linear shaped charge. Upon detonation of the/each length of linear shaped charge, a length of material is projected outwardly from the/each length of linear shaped charge towards an internal surface of die tubular, which is thereby penetrated. The at least one length of linear shaped charge is arranged such that, upon detonation, the trajectory of at least one portion of the projected material intersects the trajectory of at least one other portion of projected material at or adjacent the internal surface of the tubular.