Stackable Propellant Modules for Controlled Wellbore Pressure
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Solution Overview
Problem
The existing perforation techniques in wellbore operations often result in debris and crushed zones that hinder flow capacity, as the dynamic overbalance and underbalance events are coupled, leading to interference and inefficient well stimulation.
Innovation Solution
A stackable propellant module system that allows for controlled pressure profile generation by decoupling the perforation and gas stimulation events, using individually ignitable propellant modules with an autonomous or surface-controlled ignition system, enabling precise pressure control and efficient wellbore cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If propellant is ignited immediately after perforation to generate dynamic overbalance, then gas is rapidly produced to initiate cracks in the rock formation, but the rapid gas generation interferes with dynamic underbalance and prevents perforation tunnel clean up
Solution Approach 1:
The system divides the gas generation process into multiple segments by using a string of individually addressable propellant modules rather than a single simultaneous ignition event. This allows sequential activation of modules to create controlled pressure profiles that first establish dynamic underbalance for tunnel cleaning, then transition to dynamic overbalance for formation fracturing, thereby resolving the interference between these two opposing requirements
Solution Approach 2:
The system performs preliminary action by first creating dynamic underbalance conditions through controlled propellant ignition to clean the perforation tunnels of debris and crushed rock, before subsequently establishing dynamic overbalance conditions for formation stimulation. This sequential approach ensures that the tunnel is cleared of blockages before the main fracturing operation begins
2Productivity
If dynamic overbalance is used to stimulate the well, then cracks are initiated in the rock formation, but the crushed zone with extremely low permeability and high skin effect hinders flow capacity
Solution Approach 1:
The system applies preliminary action by first creating dynamic underbalance conditions to clean out the perforation tunnels and remove the crushed rock zone that causes high skin effect, before applying dynamic overbalance for formation stimulation. This ensures that the flow path is cleared of harmful factors before production stimulation begins
Solution Approach 2:
The system changes the pressure parameter dynamically by transitioning from negative pressure (dynamic underbalance) to positive pressure (dynamic overbalance) through controlled propellant module ignition. This parameter change enables the system to first reduce the harmful skin effect by cleaning tunnels, then increase formation flow capacity through controlled fracturing
3Power
If multiple propellant modules are ignited simultaneously to generate high pressure, then rapid gas production occurs, but precise control of pressure ramp rates is difficult
Solution Approach 1:
The system segments the propellant charge into multiple individually addressable modules that can be ignited in sequence rather than simultaneously. This segmentation enables precise control over the pressure ramp rate by activating modules at controlled time intervals, allowing the pressure to build gradually to the desired level rather than spiking abruptly
Solution Approach 2:
The system employs periodic action by igniting propellant modules at controlled time intervals rather than all at once. This periodic ignition pattern allows precise control of the pressure ramp rate, creating a stepped pressure increase that can be optimized for the specific formation conditions and well objectives
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 enhances petroleum production by separating the perforation and stimulation events, reducing equipment damage and improving flow capacity by allowing for accurate control of pressure ramp rates and reducing debris-related blockages.
Implementation Method 1
an igniter associated with the module housing and positioned to ignite the propellant
Implementation Method 2
burning propellant to rapidly produce gas
Implementation Method 3
the rapidly increased pressure and the low viscosity fluid (gas) is to flow into the reservoir and initiate cracks in the rock formation
Data Source
AI summary
This disclosure provides a stackable propellant module for use inside of a gas generation canister. The modules are designed to enable them to be individually fired rather than as a unitary mass, as done in conventional configurations. This enables the generation of a controlled pressure profile rather than an uncontrolled pressure profile determined by the environmental conditions downhole, such as temperature and pressure.