Downhole Power Charge Ignition With Gradient Propellant
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Solution Overview
Problem
Existing bridge plug setting tools require large forces, often exceeding 20,000 lbs, and unreliable electrical connections for activating power charges, which can lead to inefficiencies and potential failures in subterranean well operations.
Innovation Solution
A power charge design with a tubular housing containing a main propellant and ignition propellant mixture, where the ignition propellant has a higher propagation index and is distributed in a gradient within the housing to enhance ignition reliability and reduce activation force requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional power charges with uniform propellant distribution are used, then sufficient ignition energy is provided, but the activation force required exceeds 20,000 lbs and electrical connection reliability is compromised
Solution Approach 1:
The patent applies local quality by creating a gradient distribution of ignition propellant within the power charge, where the ignition propellant concentration varies spatially. This gradient structure provides enhanced ignition reliability at the ignition interface while reducing the overall activation force required, as the ignition propellant is concentrated where it is most needed rather than uniformly distributed throughout the entire charge.
Solution Approach 2:
The patent changes the propagation index parameter distribution within the power charge by incorporating ignition propellant with higher propagation index values in specific regions. This parameter change allows the charge to ignite more reliably with lower activation force, as the high propagation index ignition propellant facilitates faster and more reliable burn propagation from the ignition source.
2Ease of operation
If electrical connections are made to activate power charges, then setting tools can be triggered, but connection failures occur due to grounding requirements and insulation needs
Solution Approach 1:
The patent replaces the electrical activation system with a mechanical or chemical ignition system. Instead of relying on electrical connections that require grounding and insulation, the power charge is ignited through direct mechanical contact or chemical initiation, eliminating the unreliable electrical connection chain while maintaining ease of operation through simple ignition mechanisms.
3Reliability
If large activation forces exceeding 20,000 lbs are applied, then power charges can be reliably activated, but tool complexity and potential for operational failure increase
Solution Approach 1:
The patent changes the propellant composition parameters, specifically incorporating ignition propellant with higher propagation index values. This parameter change allows the power charge to be activated with significantly lower forces, reducing the complexity of the setting tool mechanism while maintaining reliable activation. The gradient distribution of ignition propellant ensures consistent ignition performance without requiring excessive activation force.
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 power charge design reduces the activation force needed for bridge plug setting and improves ignition reliability, ensuring consistent and efficient operation of downhole tools.
Implementation Method 1
The ignition propellant has a higher propagation index and is distributed in a gradient within the housing to enhance ignition reliability
Implementation Method 2
The energetic material may use a relatively slow burning chemical reaction to generate high pressure gases
Implementation Method 3
generate high pressure gases
Data Source
AI summary
A method and apparatus for igniting a power charge in downhole wellbore using an ignition propellant mixed with a main propellant, the ignition propellant may be concentrated at the first end of a housing where it is the majority propellant and then gradually mix with the main propellant, transitioning to a majority of the main propellant.