Shaped Charge Inlay for Consistent Perforation Geometry
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Solution Overview
Problem
Current shaped charges used in wellbore perforation systems produce perforations with varying entrance hole diameters and geometries, leading to unpredictable fluid distribution and pressure drops during fracturing processes, requiring multiple specialized charges and increasing costs and logistical challenges.
Innovation Solution
A shaped charge inlay is introduced, which is secured to the liner of a shaped charge, disrupting the collapse of the liner upon detonation to create atypical perforation hole geometries, including slot-shaped openings, thereby ensuring consistent entrance hole diameters and improved fluid flow, regardless of the shaped charge's geometry or position in the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional shaped charges are used for perforation, then perforation holes are created in the formation, but the entrance hole diameters vary significantly leading to unpredictable fluid distribution
Solution Approach 1:
The patent modifies the physical parameters of the shaped charge system by introducing a liner with specific geometric features (annular groove, flange portion) that control the collapse behavior. This changes the parameters of the perforating jet formation process to achieve consistent entrance hole diameters regardless of gun position or charge geometry variations.
Solution Approach 2:
The liner acts as an intermediary component between the explosive charge and the formation. It mediates the energy transfer and jet formation process, ensuring that variations in charge geometry or position do not directly translate to variations in entrance hole diameter. The liner's controlled collapse creates a standardized jet formation process.
2Adaptability or versatility
If multiple specialized shaped charges are used to achieve different perforation geometries, then specific application requirements are met, but device complexity and costs increase
Solution Approach 1:
The patent creates a universal shaped charge design that can produce different perforation geometries (slot-shaped, round, etc.) by varying the liner configuration rather than requiring completely different charge designs. The same basic charge structure can be adapted for different applications by modifying the liner's groove depth, flange position, or other geometric parameters.
Solution Approach 2:
The liner is segmented into functional zones (annular groove region, flange portion, apex) that can be independently configured. This segmentation allows different portions of the liner to control different aspects of jet formation, enabling a single charge design to achieve multiple perforation geometries by adjusting individual segment parameters.
3Productivity
If conventional shaped charges are used, then perforation holes are created, but pressure drop during fracturing is unpredictable due to varying hole geometries
Solution Approach 1:
The patent controls the geometric parameters of the perforation hole through the liner's controlled collapse. By adjusting the liner's annular groove depth, flange position, and other parameters, the entrance hole diameter and shape can be precisely controlled to optimize fluid flow characteristics and predict pressure drop during fracturing operations.
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 shaped charge inlay ensures consistent open areas for fluid flow with variations of less than 10%, reducing breakdown pressure and enhancing the efficiency of fracturing operations by creating optimal elongated openings that facilitate increased fluid flow and reduce erosion.
Implementation Method 1
shaped charges are explosive components configured to focus ballistic energy onto a target. When the detonating cord initiates the explosive load within the shaped charge, a liner and/or other materials within the shaped charge are collapsed and propelled out of the shaped charge in a perforating jet of thermal energy and solid material
Implementation Method 2
When the detonating cord initiates the explosive load within the shaped charge
Implementation Method 3
the physical force, heat, and/or pressure of the perforating jet, expelled materials, and shaped charge explosion will perforate or form entrance openings/holes in the target
Data Source
AI summary
According to some embodiments, a shaped charge inlay includes an upper edge that extends inward and horizontal to an edge of a shaped charge casing associated with a shaped charge. The shaped charge includes an existing liner and the shaped charge inlay further includes a body that extends inward toward an apex of the existing liner. The shaped charge inlay may be disposed above the existing liner in the shaped charge, to disrupt collapse of the existing liner upon detonation of the shaped charge and thereby change the geometry of a perforating jet and resulting perforation created by the shaped charge. The perforation holes formed by shaped charges having the shaped charge inlay may have geometries that include constant open areas to flow in the target when the perforating gun is centralized or decentralized in a wellbore casing.