Gas-Driven Wireline Setting Tool Stroke Control
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Solution Overview
Problem
Conventional downhole wireline setting tools are long, complex, and require multiple personnel for operation, making them inefficient and prone to human error, with a need for a more compact, cost-effective solution that can be easily tested for operational integrity before use.
Innovation Solution
A compact, gas-driven wireline setting tool with a reduced component count, utilizing a power charge to generate gas for setting downhole tools, featuring a dampening assembly and optimized flow area to regulate the setting stroke, and a method for testing the operational integrity of fluid pressure seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional wireline setting tools are used, then downhole plugs can be set, but the tools are long, complex, and require multiple personnel to handle
Solution Approach 1:
The setting tool is divided into distinct functional segments: a firing head containing the power charge and piston mechanism, a central mandrel for transmitting force, and a downhole plug assembly. This segmentation allows each component to be optimized independently and simplifies the overall operation by isolating complex functions into modular units that can be handled more easily.
Solution Approach 2:
The patent extracts the power generation function from the traditional mechanical setting tool by incorporating a self-contained power charge (propellant) within the firing head. This extraction eliminates the need for external power sources or complex mechanical linkages, significantly reducing device complexity and enabling single-person operation while maintaining the core setting function.
2Ease of operation
If conventional setting tools are used, then downhole plugs can be set, but they require multiple personnel to handle and operate
Solution Approach 1:
The setting tool incorporates a self-service power charge mechanism that automatically generates the necessary force for setting the plug when initiated. The power charge (propellant) self-ignites and expands to drive the piston and mandrel without requiring manual intervention or complex control systems, thereby enabling single-person operation while maintaining reliable automated-like functionality.
3Length of moving object
If conventional setting tools are used, then downhole plugs can be set, but they are long and require more components
Solution Approach 1:
The patent merges multiple functional components into integrated assemblies: the firing head combines the power charge, piston, and seal assembly; the central mandrel integrates the force transmission and plug engagement functions. This merging reduces the number of separate components and shortens the overall tool length while maintaining all necessary functions through compact, integrated design.
4Reliability
If conventional setting tools are used, then downhole plugs can be set, but they have more seal areas and require oil for dampening
Solution Approach 1:
The patent extracts the oil dampening system from the setting tool by replacing it with a gas-driven piston mechanism that inherently provides damping through controlled gas expansion. This extraction eliminates the need for separate dampening oil reservoirs and seal areas, reducing device complexity while maintaining reliable dampening of the setting stroke through the physics of gas compression.
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 solution results in a shorter, lighter, and easier-to-operate setting tool that can be quickly redressed and tested, reducing the risk of operational failures and human error, while ensuring proper seal functionality before deployment.
Implementation Method 1
The setting tool is functioned by selectively igniting a power charge inside of a pressure chamber formed within said pressure sub. As the power charge burns, it generates gas that acts upon a piston area to shear said shear screw(s) and stroke the setting tool.
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. A mobile testing assembly can confirm that a setting tool or other associated equipment was manufactured and assembled properly, and is fit for service, prior to running the setting tool a well bore. The mobile testing assembly and testing method can be employed in a shop or other manufacturing facility, or on a well site or other remote location.