Gas-Driven Downhole Setting Tool with Pneumatic Dampening
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Solution Overview
Problem
Conventional downhole wireline setting tools are long, complex, and require multiple personnel for operation, with many components and a need for oil damping, which increases complexity and risk of human error and leakage.
Innovation Solution
A compact, gas-driven setting tool with a simplified design that uses a power charge to generate gas for setting components, featuring a pressure sub, upper and lower sleeve members, and a central tension mandrel, with a dampening assembly and optimized flow area to regulate the setting stroke, eliminating the need for oil and reducing the number of components and potential leak paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional downhole wireline setting tools are used, then the setting function is achieved, but the tool length and complexity increase, requiring multiple personnel for operation
Solution Approach 1:
The setting tool is divided into modular components including a body, piston, setting element, and dampening assembly that can be independently manufactured and assembled. This segmentation reduces overall complexity while maintaining functionality, allowing single-person operation.
Solution Approach 2:
The oil dampening system is extracted and replaced with a gas-based dampening assembly. This removal of the oil system eliminates associated complexity (seals, leak paths, filling procedures) while achieving the same stroke regulation function through gas compression and flow restriction.
2Reliability
If conventional setting tools with oil dampening are used, then stroke regulation is achieved, but the number of components increases and leak paths are created
Solution Approach 1:
The system transitions from hydraulic (oil-based) dampening to pneumatic (gas-based) dampening. The gas compression chamber and restriction orifice provide stroke regulation without requiring seals, reservoirs, or complex fluid management systems, thereby eliminating leak paths and reducing component count.
Solution Approach 2:
The gas charge is designed as a consumable element that is replaced rather than maintained. This simple, replaceable gas charge eliminates the need for complex seal systems and fluid management, reducing both component count and maintenance requirements while improving reliability.
3Weight of moving object
If conventional setting tools are used, then the setting function is achieved, but the tool weight and length increase
Solution Approach 1:
The tool is designed as a compact, modular assembly where the piston, setting element, and dampening components are integrated into a single body. This segmentation allows for quicker disassembly and redressing while reducing overall tool weight and length compared to conventional multi-component systems.
Solution Approach 2:
The setting tool is designed for rapid redressing where spent components (particularly the gas charge and setting element) are quickly discarded and replaced. This design philosophy reduces tool weight by eliminating redundant components and enables faster redressing operations.
4Reliability
If conventional setting tools requiring oil dampening are used, then damping effect is achieved, but human error risk increases due to oil handling requirements
Solution Approach 1:
The gas compression chamber automatically provides dampening action through the inherent compressibility of gas and flow restriction via an orifice. This self-regulating system requires no manual intervention for oil filling or level monitoring, eliminating human error risks while maintaining simple operation.
Solution Approach 2:
The system uses gas instead of oil for dampening, eliminating all oil handling operations. The gas charge is contained in a sealed chamber with a restriction orifice that automatically regulates stroke speed, providing both operational simplicity and elimination of human error associated with fluid handling.
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 tool is shorter and lighter, easier to operate with fewer components, allowing single-person operation, reducing the risk of human error and leakage, and enabling quicker redressing and more efficient setting of downhole tools with improved stroke regulation.
Implementation Method 1
The setting tool of the present invention is functioned by igniting a power charge inside a firing head. As said power charge burns, the combustion generates gas that acts upon a piston area to stroke setting components of the apparatus.
Implementation Method 2
A dampening media, as well an optimized flow area at or near the distal end of the setting tool, act to slow or regulate the setting stroke.
Data Source
AI summary
A wireline conveyed, gas driven setting tool configured to set downhole tools including, without limitation, frac plugs, bridge plugs, cement retainers and packers. The setting tool is functioned by selectively igniting a power charge inside of a firing head. As the power charge burns, it generates gas that acts upon a piston area to stroke the setting tool. A dampening media, as well an optimized flow area at or near the distal end of the setting tool, act to slow the setting stroke.