Shaped Charge Effect Measurement via Digital Twin Flow Simulation
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Solution Overview
Problem
Current methods for evaluating the effect of shaped charges on rock permeability are inefficient, as they do not accurately quantify the impact of fracture patterns and tunnel geometry on fluid flow, leading to suboptimal perforation tunnel design and reduced hydrocarbon production.
Innovation Solution
A method involving the activation of a shaped charge in a rock sample to create perforation tunnels and fractures, followed by flow tests on both the sample and an analog with similar geometry, allowing for comparison of fluid flow properties to determine the shaped charge effect, thereby optimizing charge design and selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional evaluation methods are used to assess shaped charge effects on rock permeability, then the evaluation process is simple, but the measurement precision is insufficient and cannot accurately quantify the impact of fracture patterns and tunnel geometry on fluid flow
Solution Approach 1:
The patent creates a digital twin model that copies the physical rock sample's geometry, fracture patterns, and tunnel structures. This virtual replica allows repeated flow simulations without physically altering the original sample, enabling precise quantification of fracture pattern impacts while avoiding the complexity of multiple physical testing setups.
Solution Approach 2:
The patent replaces physical flow tests with computational fluid dynamics (CFD) simulations. Instead of conducting multiple physical experiments requiring complex testing equipment, the system uses numerical models to calculate fluid flow through the fracture networks and perforation tunnels, achieving higher measurement precision with reduced device complexity.
2Measurement precision
If multiple physical flow tests are conducted on different rock samples to evaluate shaped charge effects, then measurement precision improves, but loss of time increases due to repeated physical testing
Solution Approach 1:
The patent creates a digital twin model that copies the physical rock sample's geometry, fracture patterns, and tunnel structures. This virtual replica allows repeated flow simulations without physically altering the original sample, enabling precise quantification of fracture pattern impacts while avoiding the complexity of multiple physical testing setups.
Solution Approach 2:
The patent performs preliminary digital modeling and simulation to predict shaped charge effects before conducting physical tests. The computational model can be rapidly iterated with different parameters (charge design, fracture patterns, tunnel geometries) to identify optimal configurations, reducing the number of required physical experiments and associated time losses.
3Reliability
If physical flow tests are performed on actual rock samples, then reliability of results is high, but device complexity and cost increase due to specialized equipment and sample preparation
Solution Approach 1:
The patent creates a digital twin model that copies the physical rock sample's geometry, fracture patterns, and tunnel structures. This virtual replica allows repeated flow simulations without physically altering the original sample, enabling precise quantification of fracture pattern impacts while avoiding the complexity of multiple physical testing setups.
Solution Approach 2:
The patent introduces a computational model as an intermediary between the physical rock sample and the analysis process. The digital twin serves as a mediator that translates physical sample characteristics into simulatable parameters, allowing reliable permeability assessment through virtual flow tests that bypass the need for complex physical testing equipment.
4Productivity
If shaped charge design parameters are optimized based on limited experimental data, then productivity of hydrocarbon production increases, but measurement precision of fracture pattern effects remains insufficient
Solution Approach 1:
The patent implements a feedback loop where computational flow simulations provide quantitative measurements of fracture pattern impacts on fluid flow. These precise measurements feed back into the shaped charge design optimization process, allowing iterative improvement of charge parameters (geometry, liner type, positioning) to maximize hydrocarbon production while accurately quantifying fracture pattern effects.
Solution Approach 2:
The patent systematically varies multiple shaped charge design parameters (charge geometry, liner type, liner geometry, positioning) within the computational model to determine their individual and combined effects on fracture pattern formation and fluid flow. This parameter exploration enables precise quantification of fracture pattern impacts while optimizing productivity through data-driven design improvements.
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 enables precise optimization of shaped charge design, increasing hydrocarbon production by improving permeability, reducing breakdown pressures, and enhancing proppant displacement in hydraulic fracturing processes.
Implementation Method 1
the shaped charge explosion generates a set of fractures having a fracture pattern
Implementation Method 2
A shaped charge is an explosive device designed to perforate rock and produce tunnels having a specified geometry in rock
Implementation Method 3
The liner perforates the rock and generates one or more perforation tunnels
Implementation Method 4
the shaped charge explosion generates a set of fractures having a fracture pattern
Implementation Method 5
The effect that the set of fractures has on the permeability depends in part on the fracture pattern
Data Source
AI summary
A method includes determining a perforation tunnel geometry of a perforation tunnel in a solid sample, the perforation tunnel created by activating a shaped charge in proximity to the solid sample. The method also includes performing a first flow test on the solid sample and creating an analog aperture having an aperture geometry in a solid sample analog of the solid sample, wherein the aperture geometry and the perforation tunnel geometry satisfies a similarity threshold. The method also includes performing a second flow test on the solid sample analog and determining a shaped charge effect based on a comparison between a second flow test result and a first flow test result.