Disposable Downhole Setting Tool Assembly

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Solution Overview

Problem

Conventional setting tools for downhole operations are outdated, prone to damage advanced downhole tools, require maintenance, and incur high costs due to repetitive use, and often incompatible with modern wellbore technologies, especially those with horizontal deviation and sensitive electronics.

Innovation Solution

A disposable or hybrid setting tool assembly that includes a power charge mandrel with a pressure chamber and tension mandrel, eliminating the need for liquid dampeners and adapters, allowing for direct coupling with downhole tools, and utilizing a composite material for the setting sleeve to reduce weight and cost while maintaining strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional setting tools are used for downhole operations, then the tools can perform setting functions, but they are prone to damage advanced downhole tools and require maintenance

Engineering Contradiction:

Improvedamage risk to downhole toolsVSAvoidmaintenance requirements

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The setting tool assembly is designed as a disposable tool that is discarded after a single use. This eliminates maintenance requirements and reduces the risk of damage to advanced downhole tools, as the setting tool is sacrificed to protect the valuable electronics and components within the downhole tool.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If liquid dampeners are added to setting tools to reduce impact forces, then damage risk is reduced, but the tool length increases and maintenance requirements increase

Engineering Contradiction:

Improveimpact force protectionVSAvoidsetting tool length

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The disposable nature of the setting tool allows it to be designed without complex dampening systems. The tool is sacrificed after use, eliminating the need for maintainable dampeners while still providing impact protection through its sacrificial design.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If stronger materials are used in setting tools to accommodate repetitive use, then durability is improved, but capital costs increase

Engineering Contradiction:

Improvematerial strengthVSAvoidcapital cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The setting tool is designed as a single-use, disposable device that is discarded after one operation. This eliminates the need for expensive, high-strength materials required for repetitive use, significantly reducing capital costs while maintaining adequate strength for the single intended use.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of manufacture

If setting tools are designed for vertical orientation only, then manufacturing is simplified, but adaptability to modern wells with horizontal deviation is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwell orientation compatibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The setting tool assembly is designed with universal adaptability to function in both vertical and horizontal well orientations. The disposable design allows for more flexible geometries and configurations that can accommodate various well paths without significantly increasing manufacturing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 a reliable, cost-effective, and adaptable setting tool assembly that reduces the risk of damage to advanced downhole tools, eliminates the need for liquid dampeners and adapters, and is compatible with modern wellbore technologies, enhancing operational efficiency and reducing maintenance requirements.

Implementation Method 1

Ignition of the power charge may occur from various means, such as transmission of electrical current from the surface to an ignitor disposed proximate to the power charge. Once ignited, the power charge burns, which results in creating of a pressurized gas.

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS11542765B2Combination downhole assembly

Publication Date: 2023.01.03 THE WELLBOSS CO LLC

AI summary

A combination downhole assembly having a setting tool assembly coupled with a downhole tool. The setting tool assembly has an adapter housing configured to couple with a part of a workstring, and a power charge mandrel coupled with the adapter housing. There is a barrel piston releasably coupled with the power charge mandrel. During run-in, the barrel piston is in a first position. Upon activation of a setting sequence, the barrel piston moves to a second position. The setting sequence results in the barrel piston engaging a tension mandrel configured with a deceleration feature.