Downhole Power Charge Connector Alignment
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Solution Overview
Problem
Conventional downhole setting tools face reliability issues due to misalignment of the power charge with the igniter, leading to potential failure in detonation and costly, time-consuming operations when removing devices from the wellbore.
Innovation Solution
A connector system that securely attaches the power charge to the firing head via an adapter, using a collet with outer and inner engagement features to maintain alignment with the igniter, ensuring reliable detonation of the power charge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power charge is positioned within a chamber connected to the firing head, then the power charge can be contained and positioned for detonation, but misalignment with the igniter may occur leading to detonation failure
Solution Approach 1:
The connector is pre-configured with engagement features that automatically align the power charge with the igniter before detonation. The outer engagement feature engages with the adapter and the inner engagement feature engages with the power charge, preliminarily establishing correct alignment to prevent misalignment during operation.
Solution Approach 2:
The connector acts as an intermediary component between the adapter and the power charge. It mediates the connection by providing engagement features that ensure proper alignment and secure attachment, preventing direct contact issues between the adapter and power charge that could lead to misalignment.
2Reliability
If the power charge is secured in the chamber, then positioning is maintained, but misalignment may still occur causing detonation failure
Solution Approach 1:
The connector is designed with pre-configured engagement features that automatically guide and align the power charge during installation. The outer engagement feature engages with the adapter and the inner engagement feature engages with the power charge, preliminarily establishing correct alignment to prevent misalignment during operation.
Solution Approach 2:
The connector serves as an intermediary that simplifies the installation process by providing built-in alignment features. It mediates between the adapter and power charge, making the operation easier by automatically ensuring proper alignment without requiring complex adjustment procedures.
3Reliability
If a connector with engagement features is used to attach the power charge, then alignment reliability is improved, but device complexity increases
Solution Approach 1:
The connector is segmented into distinct engagement features: an outer engagement feature that interfaces with the adapter and an inner engagement feature that interfaces with the power charge. This segmentation allows each feature to be optimized for its specific function while maintaining overall simplicity.
Solution Approach 2:
The connector serves multiple functions simultaneously: it attaches the power charge to the adapter, maintains alignment, and prevents misalignment during operation. By consolidating these functions into a single component with engagement features, the design achieves high reliability without proportionally increasing 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 connector system enhances the reliability of power charge detonation by preventing misalignment, thereby improving the success rate of setting devices within the wellbore and reducing operational costs and time.
Implementation Method 1
The primary igniter often comprises black powder (e.g., gun powder, a mixture of sulfur, charcoal, and saltpeter) that is ignited from the electrical signal
Implementation Method 2
The power charge is detonated to generate the force required to set the device. For example, the force from the detonated power charge may move a piston causing the setting of the device
Data Source
AI summary
A downhole setting tool and method of using the setting tool, the setting tool including a firing head, an igniter, a housing connected to the firing head, a power charge positioned within a chamber of the housing, and a connector connecting a portion of the power charge to the firing head. The connector may be connected to the uphole end of the power charge. The connector may connect the power charge to an adapter that connects the power charge to the firing head. The connector may be a ring having an outer engagement feature that engages the adapter and an inner engagement feature that engages the power charge. The connector may be a collet including an outer engagement feature that engages the adapter and a plurality of fingers that engage the power charge. The ignitor is used to detonate the power charge to set a device within a wellbore.