Downhole Power Charge Ignition via Embedded Heating Element
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Solution Overview
Problem
Existing downhole tools face challenges in reliably transmitting electrical signals for detonating explosive charges and setting bridge plugs, particularly due to the need for complex electrical connections and high forces required for plug setting, which can lead to inefficiencies and tool stress.
Innovation Solution
A power charge cartridge assembly with a heating element, such as an electrical resistor, is integrated into the tool, allowing for addressable electrical energy application to ignite the energetic material directly, eliminating the need for a separate igniter and optimizing gas expansion for reduced tool stress and increased reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate igniter is used to detonate the power charge, then the ignition function is achieved, but the tool complexity increases and reliability decreases due to additional electrical connections
Solution Approach 1:
The heating element is integrated directly into the power charge cartridge assembly, merging the ignition function with the power charge itself. This eliminates the need for a separate igniter and its associated electrical connections, thereby reducing tool complexity while maintaining ignition reliability.
Solution Approach 2:
The igniter function is extracted from the power charge assembly and replaced by a heating element that can be directly energized through the power charge's electrical connections. This extraction eliminates the need for separate igniter components and their associated electrical infrastructure.
2Ease of operation
If high forces are applied to set bridge plugs, then the plug setting function is achieved, but tool stress increases and device durability decreases
Solution Approach 1:
The mechanical force required to set bridge plugs is replaced by a pneumatic system. A pneumatic piston generates the necessary expansion force to set the bridge plug, eliminating the need for high mechanical forces that cause tool stress and improve tool durability.
Solution Approach 2:
A pneumatic piston is introduced to generate the force needed to set the bridge plug. The pneumatic system provides the necessary expansion force through gas pressure, replacing direct mechanical forcing and reducing stress on the tool components.
3Extent of automation
If complex electrical connections are used to transmit signals downhole, then the electrical signal transmission is achieved, but the reliability decreases due to connection failures
Solution Approach 1:
The separate igniter and its associated electrical connections are extracted from the system. The heating element is integrated into the power charge cartridge assembly, reducing the number of electrical connections needed and thereby improving connection reliability.
Solution Approach 2:
The electrical system is segmented to minimize connection points. By integrating the heating element directly into the power charge cartridge assembly, the electrical connections are localized and reduced, improving reliability by eliminating potential failure points in the electrical transmission path.
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
This solution ensures reliable ignition of the power charge without a separate igniter, simplifies tool complexity, and enhances the efficiency of gas expansion, reducing stress on the tools and enabling greater reusability.
Implementation Method 1
A power charge cartridge assembly with a heating element, such as an electrical resistor, is integrated into the tool, allowing for addressable electrical energy application to ignite the energetic material directly
Implementation Method 2
The energy of the exploding detonating cord can ignite shaped charges that are properly placed proximate to the detonating cord
Data Source
AI summary
A method and apparatus for detonating a power charge in downhole wellbore using a heating element embedded within the energetic material of the power charge.