Bridge Plug Pressure Intensifier Module for Higher Setting Force
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Solution Overview
Problem
Existing bridge plugs require additional setting force for certain applications, and redesigning downhole power units (DPUs) to provide this force is complex and costly.
Innovation Solution
A pressure intensifier module is retrofitted onto the bridge plug to amplify the setting force by using a force-dependent coupling device that activates above a threshold, allowing the DPU to transmit force through a movable cylinder and intensifier piston, which multiplies the setting force via hydraulic pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a new DPU is designed to provide additional setting force, then the setting force is improved, but the device complexity and cost increase
Solution Approach 1:
The system is divided into two functional parts: the existing DPU that provides base force and the separate pressure intensifier module that provides force multiplication. This segmentation allows the DPU to remain unchanged while adding intensification capability through a modular component that attaches to the bridge plug.
Solution Approach 2:
The pressure intensifier module acts as an intermediary between the DPU and the bridge plug setting mechanism. It receives force from the DPU and transforms it into amplified setting force through hydraulic pressure, serving as a mediating component that enables force multiplication without modifying the DPU.
2Reliability
If the setting force is increased for challenging applications, then the anchoring reliability is improved, but the device complexity increases
Solution Approach 1:
The pressure intensifier module utilizes hydraulic principles to multiply the setting force. A piston with a large area receives force from the DPU and generates amplified force through hydraulic pressure, providing reliable anchoring in challenging applications without increasing mechanical complexity.
Solution Approach 2:
The system changes the pressure parameter by creating a pressure differential across the piston in the pressure intensifier module. This parameter change enables force multiplication, allowing the same DPU to provide adequate setting force for more demanding applications by adjusting pressure rather than increasing mechanical complexity.
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 additional setting force without redesigning the DPU, ensuring secure anchoring and sealing, even under temperature variations, and maintaining tool integrity during thermal cooldowns.
Implementation Method 1
The pressure intensifier piston is configured to output a setting force to a setting piston... the setting force is generated, at least in part, by the pressure intensifier piston
Data Source
AI summary
Some implementations include an apparatus configured for use in a wellbore drilled through one or more subsurface formations. The apparatus may comprise one or more pressure intensifier modules configured to increase an applied force of a downhole power unit (DPU) in setting a downhole tool in the wellbore, each pressure intensifier module including a movable input device configured to provide an input force from the DPU and a pressure intensifier piston having a first portion of a first contact area and a second portion of a second, smaller contact area, wherein the pressure intensifier piston is coupled to the movable input device by a force-dependent coupling device. The apparatus may also include a setting piston configured to provide a setting force to one or more components of the downhole tool, wherein the setting force is generated, at least in part, by the pressure intensifier piston.