Downhole Torch Adapter for Obstruction Removal
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Solution Overview
Problem
Existing methods for removing downhole obstructions and inoperable equipment in wellbores often cause further obstruction, damage to the wellbore walls, and inefficiencies due to misalignment and movement of cutting devices, leading to costly delays and incomplete removals.
Innovation Solution
An apparatus comprising a tubular body with a nozzle and a fuel load, such as molten thermite, and an adapter with protruding elements for precise alignment and protection, which projects the fuel load to erode or penetrate obstructions while minimizing damage to the surrounding area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drilling, cutting, or consuming methods are used to remove obstructions, then the obstruction can be removed, but damage is caused to the inner wall of the wellbore and further obstruction occurs
Solution Approach 1:
A centrally positioned adapter acts as an intermediary between the torch and the obstruction, providing a protected pathway for the cutting flame while preventing direct contact with the wellbore walls. The adapter includes a centrally positioned flame path that channels the cutting flame directly at the obstruction, eliminating harmful lateral spread to the wellbore inner wall.
Solution Approach 2:
The adapter is divided into multiple functional segments: a body portion that positions the torch, a centrally positioned flame path that directs the cutting flame, and a barrier portion that blocks harmful flames. This segmentation allows each component to perform its specific function in protecting the wellbore while maintaining effective obstruction removal.
2Reliability
If cutting devices are used to remove obstructions, then the obstruction can be removed, but the cutting device swings or moves causing misalignment and incomplete removal
Solution Approach 1:
The adapter is positioned and secured on the torch before the cutting operation begins. This preliminary positioning establishes a fixed, centrally aligned flame path that prevents any swing or movement during the cutting process, ensuring complete and accurate obstruction removal without requiring realignment.
Solution Approach 2:
The adapter serves as a stable intermediary structure that fixes the relative position between the torch and obstruction. By providing a rigid, centrally positioned flame path, it eliminates the misalignment and swinging that would otherwise occur during the cutting operation.
3Productivity
If conventional torches are used without protective barriers, then the cutting operation can proceed, but damage occurs to surrounding areas including wellbore walls and casing
Solution Approach 1:
A barrier portion is introduced as an intermediary element between the uncontrolled flame and the surrounding wellbore structure. This barrier selectively blocks harmful flames from reaching the wellbore walls and casing while allowing the cutting flame to pass through the centrally positioned flame path and effectively remove the obstruction.
Solution Approach 2:
The adapter provides localized protection by creating a controlled flame environment. The barrier portion is strategically positioned to block harmful flames in specific directions toward the wellbore walls, while the centrally positioned flame path maintains cutting effectiveness at the obstruction location.
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 solution enables accurate and efficient removal of downhole obstructions and tools by aligning the cutting device with the obstruction, preventing damage to the wellbore walls, and ensuring complete removal with reduced operational delays and costs.
Implementation Method 1
The fuel load is initiated to produce a molten thermite
Implementation Method 2
projecting the molten thermite onto the obstruction or the downhole tool to modify or remove the obstruction or the downhole tool
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Apparatus and adapter are usable for aligning downhole torch apparatuses and cutting devices, including axial pyro torches, circulating pyro torches, and radial cutting and perforating torches, within a wellbore for removal of one or more downhole obstructions. The torch and/or cutting apparatus comprises a body having a nozzle adapted to project a fuel load, such as molten thermite or molten thermite with a polymer, in a direction aligned with the obstruction. The adapter comprises protruding elements for eliminating or diminishing damage to the area surrounding the obstruction, including the inner walls of the wellbore and/or casing, and can further comprise centralizers for alignment of the apparatus with the obstruction, within the wellbore.