Fixed-Volume Setting Tool Assembly for Consistent Downhole Gas Pressure
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Solution Overview
Problem
The uncertainty in the total combustion volume of conventional downhole setting tools, due to separate components like firing heads and adapters, leads to inconsistent gas generation, potentially causing damage, leakage, or failure of downhole tools, and inefficient use of power charge material.
Innovation Solution
A fixed-volume power charge initiator assembly is integrated into the setting tool, which includes a pressure block and cartridge forming a sealed combustion chamber, ensuring a known volume and precise gas generation, eliminating the need for external firing heads and reducing uncertainty in combustion volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate firing heads and setting tools are combined, then the setting tool can be operated remotely, but the total combustion volume becomes uncertain leading to inconsistent gas generation
Solution Approach 1:
The patent merges the firing head and setting tool into a single integrated unit with a defined internal combustion chamber. The power charge is contained within the setting tool itself rather than being separate, creating a fixed and known combustion volume that ensures consistent gas generation while maintaining remote operation capability through the integrated igniter system.
2Reliability
If a fixed volume combustion chamber is created, then gas generation becomes precise and consistent, but the device complexity increases due to additional sealing components
Solution Approach 1:
The combustion chamber is segmented into distinct sealed regions using O-rings and sealing surfaces at specific locations. This segmentation approach creates discrete pressure zones that maintain fixed volume while using standardized sealing components rather than complex continuous sealing structures, thereby achieving reliability with controlled complexity.
3Reliability
If the power charge is contained within the setting tool, then combustion volume is fixed and known, but the loss of substance increases due to confined powder containment
Solution Approach 1:
The power charge powder is extracted from external containers and directly contained within the combustion chamber of the setting tool during manufacturing. This eliminates transfer operations that could cause powder loss and ensures the entire intended charge is contained within the fixed volume, achieving both precision and reduced substance loss.
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
Ensures consistent and efficient gas pressure for tool activation, preventing damage and leakage, optimizing power charge use, and ensuring reliable operation of downhole tools.
Implementation Method 1
a power charge disposed within the combustion chamber
Data Source
AI summary
In the context of downhole tools, fixed volume power charge initiator assemblies and bottom hole assemblies utilizing fixed volume power charge initiator assembly are disclosed. The fixed volume power charge initiator assembly has a pressure bulkhead coupled to a cartridge. The cartridge includes an igniter disposed within an interior cavity of the cartridge. When used in a bottom hole assembly the fixed volume power charge initiator assembly is located in a setting tool adjacent to a power charge located within a combustion chamber of the setting tool. The combustion chamber and the cartridge together define a fixed total combustion volume. In some instances, the fixed volume power charge initiator assembly includes a power charge detector switch. Other assemblies are discussed.