Downhole Actuator Bidirectional Operation and Pressure Equalization
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Solution Overview
Problem
Existing downhole actuator devices for setting and releasing plugs or packers are limited by unidirectional operation, high costs, complexity, and reliance on specific drive modules, which can result in tools becoming permanently attached to partially set plugs due to failures, and insufficient actuation force for higher pressure applications.
Innovation Solution
A dual-stage actuator device with modular and stackable design, capable of bidirectional operation, utilizing a dual bore configuration to recirculate hydraulic fluid and provide high forces without increasing operating pressure, and incorporating a pressure dump valve for safe release from partially set plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unidirectional actuator devices are used for setting plugs or packers, then the device complexity is reduced, but the reliability decreases due to tool entrapment from failures
Solution Approach 1:
The patent applies bidirectional actuation capability to the setting tool, allowing the tool to both set and release plugs or packers. This inversion of the traditional unidirectional approach enables the tool to reverse its action, preventing entrapment in case of failure while maintaining reasonable complexity through controlled bidirectional operation
2Force
If higher operating pressure is used to increase actuation force, then the force capability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent employs a dual-stage actuator design that multiplies force through mechanical advantage rather than simply increasing pressure. The first stage piston drives the second stage piston, creating a force multiplication effect that achieves high actuation force without proportionally increasing operating pressure or system complexity
3Adaptability or versatility
If non-modular actuator devices are used, then the device complexity is reduced, but the adaptability decreases for different drive modules
Solution Approach 1:
The patent implements a modular actuator design where the first stage actuator, second stage actuator, and control system can be independently configured and combined. This segmentation allows different drive modules (hydraulic, pneumatic, electric) to be interfaced with the core bidirectional actuation mechanism, enhancing adaptability while managing complexity through standardized interfaces
4Force
If single-stage actuation systems are used, then the device complexity is reduced, but the force capability is insufficient for high pressure applications
Solution Approach 1:
The patent employs a nested dual-stage configuration where the second stage piston is positioned within the first stage actuator assembly. The first stage piston drives hydraulic fluid that actuates the second stage piston, creating a compact nested arrangement that multiplies force while minimizing overall device complexity and space requirements
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
Enables efficient setting and releasing of high-force requirements, reduces tool length, and prevents tool entrapment by allowing bidirectional operation and pressure equalization, thus enhancing operational flexibility and safety.
Implementation Method 1
fluid is provided to a first bore of the inner rod to act between piston faces defined by the inner rod and the outer housing to move the outer housing relative to the inner rod
Implementation Method 2
dual bore configuration to recirculate hydraulic fluid and provide high forces without increasing operating pressure
Implementation Method 3
incorporating a pressure dump valve for safe release from partially set plugs
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
The invention provides an actuator assembly for a downhole tool and a method of use. The actuator assembly comprises an actuator device, which includes a housing and a piston element movable with respect to the housing. First and second fluid paths are configured to couple first and second sides of the piston element to at least one source of fluid pressure in a drive module, and an actuator member is configured to be coupled to a downhole device. The actuator member is movable between a first position and a second position to operate the downhole device in response to a force acting on the piston element. The actuator assembly comprises a pressure release mechanism which is operable to equalise pressure between the first and second fluid paths of the actuator device. The invention may be used in conjunction with a valve module which includes the pressure release mechanism, and the valve member preferably comprises a forward flow position, in which a first side of the piston element is pressurised to urge the piston element in a first direction, and a reverse flow position in which a second side of the piston element is pressurised to urge the piston element in a second direction, opposite the first direction. A preferred embodiment of the invention is setting tool incorporating the actuator assembly.