Downhole Power Switch Actuator for Pressure-Sealed Activation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing downhole tools in the oil and gas industry require time-consuming and specialized procedures to activate mechanical switches, involving pressure barrier disassembly and reassembly, which can lead to battery depletion and switch failure due to magnetization in wellbores, necessitating larger battery capacities and certified technicians.
Innovation Solution
An actuator assembly that allows actuation of a mechanical switch without power, using a switch plunger and actuator to toggle the switch between positions while maintaining pressure, eliminating the need for pressure barrier disassembly and specialized certification, and enabling easy assembly and disassembly of downhole tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical switch is used to connect the battery to the electronics, then the tool can be powered on, but the pressure barrier must be disassembled and reassembled which consumes time and requires specialized technicians
Solution Approach 1:
The tool is divided into separate functional modules: a pressure-containing module that maintains pressure isolation, and a switch actuation module that can be operated independently. This segmentation allows the switch to be activated without compromising the pressure barrier integrity, eliminating the need to disassemble and reassemble pressure-containing components.
Solution Approach 2:
A magnetic field is introduced as an intermediary to actuate the mechanical switch. The magnetic field can penetrate the pressure barrier without physical contact, allowing the switch to be toggled from the outside without disassembling the pressure-containing module. This intermediary mechanism resolves the contradiction by enabling switch activation while maintaining pressure isolation.
2Ease of operation
If the tool is activated at the surface before deployment, then the switch can be turned on, but the battery depletes during the time before the tool reaches target depth
Solution Approach 1:
The tool is prepared with all necessary components assembled and the pressure barrier installed before deployment. The switch remains in the off position during transport, and activation occurs automatically or on-demand at the target depth. This preliminary preparation eliminates the need for premature activation, preserving battery life during the transit phase while ensuring the tool is ready for immediate operation upon arrival.
3Ease of operation
If magnetically actuated switches are used to activate the tool from outside, then pressure barrier disassembly is eliminated, but the metallic materials become magnetized in the wellbore causing switch failure
Solution Approach 1:
Instead of using permanent magnetic materials that become magnetized and fail, the invention employs a temporary magnetic field application. The magnetic field is applied only during the brief moment of switch actuation and then removed. This approach uses a 'disposable' magnetic influence that does not leave residual magnetization in the metallic components, thereby maintaining switch reliability while achieving remote actuation.
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
Reduces rig time, eliminates pressure testing requirements, and allows tools to be easily turned on and off, reducing battery size and need for specialized technicians, while maintaining a seal and preventing switch failure.
Implementation Method 1
A method of actuating a mechanical switch on a battery-powered downhole tool includes moving, by means of a magnetic field, a plunger of an actuator
Data Source
AI summary
In general, in one aspect, embodiments relate to an actuator assembly, that includes a plunger housing, a switch plunger disposed within the plunger housing, and a switch actuator configured to induce linear movement of the switch plunger along the plunger housing, where the actuator assembly is configured to change between an ON position and an OFF position by moving the switch plunger between extended and non-extended positions, and maintain a first pressure at one end of the switch plunger when an outer portion of the actuator assembly is exposed to a second pressure greater than the first pressure.