Tubular Wall Patterning for Heat Transfer and Collapse Resistance
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Solution Overview
Problem
Downhole tubulars face limitations in collapse strength and heat transfer surface area, with traditional methods like finning being impractical due to space constraints and fragility, and existing patterning techniques being expensive and unsuitable for in-situ applications.
Innovation Solution
A method involving laser, electron beam, or radiation patterning of tubular walls with differential pressure application to enhance heat transfer surface area and collapse resistance, using an insert with a raised pattern or vacuum to deform the tubular wall, allowing for in-situ processing in boreholes or surface facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional finning methods are used to enhance heat transfer surface area, then heat transfer efficiency is improved, but the structure becomes fragile and space-consuming which is impractical for downhole applications
Solution Approach 1:
The patent applies localized hardening to specific regions of the tubular wall rather than uniformly treating the entire structure. By creating hardened zones at intervals along the tubular, the structure gains localized strength and surface area enhancement while maintaining overall flexibility and reducing fragility. This selective application of treatment allows heat transfer enhancement without the brittleness associated with complete structural modification.
Solution Approach 2:
The invention transitions from adding external fins (one-dimensional surface addition) to creating three-dimensional surface irregularities through localized hardening and deformation. The hardened zones are plastically deformed to create protrusions and surface area multiplication in multiple dimensions, achieving enhanced heat transfer without external attachments that would be fragile or space-consuming.
2Area of stationary object
If multiple nested tubulars are expanded to create heat transfer surfaces, then heat transfer area is increased, but fabrication complexity and cost increase significantly
Solution Approach 1:
Instead of using multiple nested tubulars, the invention segments the treatment process into discrete localized hardening zones along a single tubular. Each zone is independently treated and can be selectively deformed to create heat transfer surfaces. This segmentation approach achieves multi-surface functionality within a single-walled structure, reducing fabrication complexity while maintaining increased heat transfer area.
Solution Approach 2:
The patent replaces complex mechanical nesting and expansion of multiple tubulars with a field-based approach using laser or electron beam hardening followed by controlled plastic deformation. This substitution of mechanical fabrication with energy field treatment and controlled deformation simplifies the fabrication process while achieving the same functional result of increased heat transfer surface area.
3Manufacturing precision
If shop fabrication methods are used to pattern tubulars, then manufacturing precision is achieved, but the process cannot be performed in-situ in boreholes
Solution Approach 1:
The invention creates a universal treatment system that can operate in multiple environments - both in-shop fabrication settings and in-situ borehole conditions. The laser or electron beam hardening process, combined with differential pressure application, can be performed regardless of location. This multi-functionality allows the same precise patterning technique to be applied whether the tubular is on the surface or already installed in a borehole, eliminating the need for different fabrication approaches based on location.
Solution Approach 2:
The method allows preliminary hardening patterning to be performed before the tubular is installed in the borehole, with the option to complete or enhance the process in-situ. The localized hardening creates a precursor structure that can then be deformed by differential pressure applied either during fabrication or after installation. This preliminary action enables precision patterning while maintaining the flexibility to complete the process in the optimal location.
4Ease of operation
If thin-walled tubulars are used to maintain borehole flexibility, then ease of operation is improved, but collapse resistance decreases
Solution Approach 1:
The patent applies localized hardening to specific circumferential zones of the tubular wall rather than uniformly thickening the entire structure. These hardened zones act as reinforcement rings that resist collapse while leaving the intervening sections of thin wall to maintain flexibility. This selective localization of material properties allows the tubular to exhibit both high collapse resistance at critical points and high flexibility in the overall structure.
Solution Approach 2:
The tubular wall is segmented into alternating zones of hardened material and thin wall sections. The hardened segments provide structural support and collapse resistance, while the thin wall segments maintain flexibility and ease of operation. This segmentation of material properties along the tubular length allows simultaneous optimization of both strength and flexibility without requiring uniform wall thickness increase.
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 method effectively increases heat transfer surface area and collapse resistance of tubulars, enabling more efficient geothermal and SAGD operations while being cost-effective and adaptable to various patterns and environments.
Implementation Method 1
A pattern is applied to an interior wall with laser, electron beam or radiation that is remotely controlled to apply the hardening pattern to the inside wall
Implementation Method 2
A pattern is applied to an interior wall with laser, electron beam or radiation that is remotely controlled to apply the hardening pattern to the inside wall
Implementation Method 3
A pattern is applied to an interior wall with laser, electron beam or radiation that is remotely controlled to apply the hardening pattern to the inside wall
Implementation Method 4
Pressure differential is applied to the wall so that the non-hardened portions or the negative of the hardened pattern plastically and/or elastically deform to increase surface area
Implementation Method 5
Pressure differential is applied to the wall so that the non-hardened portions or the negative of the hardened pattern plastically and/or elastically deform to increase surface area
Data Source
AI summary
A process for hardening tubulars and increasing their surface area for heat transfer can be performed in place in a borehole or on the surface. A pattern is applied to an interior wall with at laser, electron beam or radiation source that is remotely controlled to apply the hardening pattern to the inside or outside wall as inert gas or clean fluid is applied. Pressure differential is applied to the wall so that the non-hardened portions or the negative of the hardened pattern plastically or elastically deform to increase surface area and enhance load resistance of tubular or sheets. Alternatively, wall differential pressure is applied with an insert having a raised pattern on its exterior surface causing the spaces where the pattern is absent to plastically deform to enhance surface area. When done in a borehole annulus pressure or stand pipe pressure is applied or a vacuum is pulled inside the tubular to generate differential pressure for hydro-forming or switching dents in an opposite stable condition. The insert can be removed mechanically, or by dissolving or disintegration. Geothermal and SAGD applications are envisioned.