Integrated Downhole Plug and Perforating Tool for Single-Run Well Killing

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Solution Overview

Problem

Current methods for preparing a well for well killing operations require separate runs to perforate and plug production tubing, which are time-consuming and costly due to the significant depth of oil wellbores.

Innovation Solution

A downhole tool that integrates both plugging and perforating capabilities, allowing a single run to seal and create a perforation in the production tubing, facilitating the introduction of kill fluid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate runs are made to lower a perforation tool and a plugging tool separately, then each function can be performed reliably, but the time and cost increase significantly

Engineering Contradiction:

Improveperforation and plugging function reliabilityVSAvoidtime for well preparation

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent combines the perforation tool and plugging tool into a single integrated downhole tool assembly. The perforation device with cutting elements and the plug setting mechanism are housed together in one tool string, allowing both functions to be performed in a single run. This merging eliminates the need for separate perforation and plugging runs, directly reducing time and cost while maintaining the reliability of each individual function through proven design elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The downhole tool is designed as a multi-functional device that can both perforate the production tubing and set a plug in a single operation. The tool housing contains both the perforating mechanism with rotatable cutting elements and the plug setting system, enabling one tool to perform multiple functions that previously required separate specialized tools. This universality maintains operational reliability while eliminating the time loss associated with multiple tool deployments.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate runs are made to perforate and plug the production tubing, then specialized tools can be used for each function, but the operational cost increases

Engineering Contradiction:

Improvespecialized tool capabilityVSAvoidoperational cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges the specialized perforation tool and plugging tool into a single integrated assembly. The tool housing accommodates both the perforating mechanism with cutting elements and the plug setting system, allowing both specialized functions to be performed by one tool string. This reduces operational costs by eliminating the need for two separate tool deployments while preserving the specialized capabilities of each function through careful integration of proven design elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The downhole tool achieves universality by incorporating both perforation and plugging capabilities in a single device. The tool can adapt to perform either function or both functions sequentially in one run, replacing the need for separate specialized tools. This multi-functionality reduces operational costs while maintaining the specialized performance required for each function through dedicated mechanisms within the unified tool design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If a single downhole tool combines plugging and perforating functions, then time and cost are reduced, but the device complexity increases

Engineering Contradiction:

Improvewell preparation efficiencyVSAvoiddownhole tool structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The integrated downhole tool is segmented into distinct functional modules: a perforation device with rotatable cutting elements, a plug setting mechanism, and a housing that accommodates both systems. This segmentation allows each function to be independently designed and optimized while being integrated into a single tool string. The modular structure manages complexity by organizing functions into separate but coordinated components, enabling high productivity through single-run operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a nested structure where the plug and setting mechanisms are housed within the tool housing that also contains the perforation device. The plug can be nested within the tool assembly during deployment and then deployed into the production tubing. This nesting approach consolidates multiple functions into a compact integrated tool, managing structural complexity while achieving the productivity benefits of combined operations in a single run.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12534973B2Downhole tool

Publication Date: 2026.01.27 SAUDI ARABIAN OIL CO

AI summary

A downhole tool includes a plugging portion including a plug transitionable between a running state, where the plug is retracted and allows the downhole tool to traverse an interior of production tubing, and a plugging state, where the plug expands radially outward to sealingly engage an inner wall of the production tubing. A perforating portion is operatively coupled to the plugging portion and provides a housing that houses a perforating device actuatable to penetrate the inner wall of the production tubing and thereby generate a perforation through which a kill fluid may be circulated into an annulus surrounding the production tubing.