Ballistically Actuated Wellbore Plug for Rapid Zone Isolation

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Solution Overview

Problem

Existing wellbore plug-and-perf operations face issues such as increased tool string length, handling difficulties, debris creation, and inaccurate positioning due to mechanical processes, which are addressed by integrating a ballistically actuated plug that instantaneously expands within the wellbore casing.

Innovation Solution

A ballistically actuated plug with a ballistic housing and detonation extender that expands upon detonation to secure within the wellbore casing, eliminating the need for a setting tool and mechanical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a setting tool is used to deploy the plug, then the plug can be expanded to isolate the wellbore zone, but the tool string length increases and handling becomes more difficult

Engineering Contradiction:

Improveplug expansion reliabilityVSAvoidtool string length

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The plug and setting tool are merged into a single integrated assembly where the plug housing contains both the plug body and the setting mechanism. This integration eliminates the need for separate setting tools and reduces the overall tool string length while maintaining reliable plug expansion capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The setting mechanism is nested within the plug housing structure. The setting tool components are positioned inside the hollow interior of the plug, allowing the plug to be deployed as a self-contained unit without requiring additional external setting tools, thereby reducing tool string length.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If a setting tool with mechanical components is used, then the plug can be expanded, but debris is created and handling precision is reduced

Engineering Contradiction:

Improveplug expansion capabilityVSAvoiddebris creation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The traditional mechanical piston-based expansion system is replaced with a ballistic actuation system. A ballistic component (such as a shaped charge or explosive charge) is positioned within the plug housing and, when activated, directly expands the plug body through controlled detonation, eliminating mechanical debris and improving handling precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The expansion mechanism utilizes phase transition of explosive materials from solid to gas/energy state during detonation. This phase transition generates the necessary expansion force directly within the plug housing, avoiding mechanical contact and debris generation while maintaining reliable plug expansion.

Inventive Principle:

Principle #36Phase transitions

3Reliability

If a setting tool is used for plug deployment, then the plug can be expanded to seal the wellbore, but the operation time is increased

Engineering Contradiction:

Improvezone isolation reliabilityVSAvoidoperation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The plug is pre-assembled with the setting mechanism and ballistic components integrated within the hollow interior during manufacturing. This preliminary integration eliminates the need for on-site assembly operations and reduces the overall operation time while maintaining reliable zone isolation when the plug is deployed and activated.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The ballistic actuation system provides continuous and immediate expansion action upon activation, eliminating the step-by-step mechanical operation sequence required by traditional setting tools. This continuous action reduces operation time while ensuring reliable and consistent plug expansion for zone isolation.

Inventive Principle:

Principle #20Continuity of useful action

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 provides instantaneous expansion and secure sealing within the wellbore, reducing tool string length, minimizing debris, and enhancing operational precision and efficiency.

Implementation Method 1

an initiator is positioned within the chamber. A detonation extender may be in ballistic communication with the initiator and may be circumferentially disposed around the noncompressible core of the second housing portion. The detonation extender is configured, upon detonation, to expand the outer seal housing from an unexpanded form to an expanded form

Methodology Applied

Scientific EffectDetonation: Detonation

Data Source

PatentUS12410667B2Ballistically actuated wellbore tool

Publication Date: 2025.09.09 DYNAENERGETICS EURO GMBH

AI summary

A ballistically actuated plug (2100) for being deployed in a wellbore casing includes a ballistic housing (2106) and an outer seal housing (2102). The ballistic housing includes a first housing portion including a chamber (2208), and a second housing portion having a noncompressible core. The outer seal housing is circumferentially disposed around the noncompressible core (2216). According to an aspect, the initiator (2206) is positioned within the chamber and a detonation extender (2222) is in ballistic communication with the initiator and is circumferentially disposed around the noncompressible core. The detonation extender is configured to, upon detonation, expand the outer seal housing (2102) from an unexpanded form to an expanded form to secure the outer seal housing within the wellbore casing.