Hydraulic Setting Tool for Downhole Actuation
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Solution Overview
Problem
Existing well tools require separate intervention runs or communication links to actuate downhole devices like packers or valves, which is inefficient and often necessitates operator intervention.
Innovation Solution
A modular setting tool that uses sensing and actuation modules to interpret commands and actuate downhole devices using pressure pulses, electric or electromagnetic signals, or pressure delivery, allowing for autonomous operation without integral connection to specific tools, utilizing a power generation module with rupture discs and intensifiers to manage hydrostatic pressure and temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate intervention runs using mechanical or electrical actuators are used to actuate downhole devices, then the downhole devices can be actuated, but the operation efficiency decreases and additional intervention time is required
Solution Approach 1:
The patent combines the actuation function directly into the downhole device by integrating a setting tool with hydraulic actuator that can be actuated through pressure pulses transmitted via the wellbore fluid, eliminating the need for separate intervention runs with mechanical or electrical actuators. This merging of actuation capability into the device itself resolves the contradiction by improving productivity while reducing intervention time.
Solution Approach 2:
The patent uses pressure pulses transmitted through wellbore fluid as an intermediary medium to actuate the downhole device remotely. Instead of requiring direct mechanical or electrical connection, the control signal is transmitted through the fluid medium, enabling remote actuation without additional intervention runs, thus improving operation efficiency and reducing time loss.
2Reliability
If communication links such as hydraulic or electrical control lines are run with the tool to actuate downhole devices, then reliable actuation is achieved, but the device complexity and installation difficulty increase
Solution Approach 1:
The patent utilizes the wellbore fluid serving multiple functions: it acts as both the drilling/production medium and the control signal transmission medium. The same fluid that fills the wellbore for operational purposes is also used to transmit pressure pulses for actuation, eliminating the need for separate hydraulic or electrical control lines. This multi-functionality maintains actuation reliability while reducing device complexity.
Solution Approach 2:
The patent extracts the actuation function from separate communication lines and integrates it into the existing wellbore fluid system. By removing the need for dedicated control lines and using the already-present wellbore fluid for signal transmission, the solution maintains reliable actuation while significantly reducing overall system complexity.
3Adaptability or versatility
If the setting tool is designed to work in a wide range of hydrostatic pressures and temperatures, then the adaptability to different environments is improved, but the device complexity increases
Solution Approach 1:
The patent employs rupture discs with different burst pressures and thermal-sensitive materials that change properties at specific temperatures. These components are designed to respond to variations in hydrostatic pressure and temperature by changing their state (rupturing or expanding), enabling the tool to adapt to different environmental conditions without requiring complex active control systems. This passive parameter-based adaptation resolves the contradiction by improving environmental versatility while minimizing device complexity.
4Ease of operation
If autonomous operation without integral connection to specific tools is implemented, then the ease of operation and reduction of operator intervention is achieved, but the sensing and actuation system complexity increases
Solution Approach 1:
The patent implements autonomous operation where the downhole device performs its own actuation by sensing pressure pulses or thermal changes in the wellbore fluid and automatically responding through pre-programmed mechanisms. The device serves itself by using the environmental signals directly to trigger actuation without requiring external control systems or operator intervention. This self-service approach reduces operational complexity despite the inherent complexity of the sensing and actuation modules.
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
Enables efficient, autonomous actuation of downhole devices across various environments and pressures, reducing operator error and intervention needs, while ensuring reliable operation and adaptability to different hydrostatic conditions.
Implementation Method 1
designed to work in a wide range of hydrostatic pressures
Implementation Method 2
power generation module with rupture discs and intensifiers to manage hydrostatic pressure
Data Source
AI summary
A tool is actuated in a well based on one or more issued commands being interpreted and implemented by the apparatus. The apparatus comprises a power generation module that multiplies pressure delivered downhole to enable actuation of the tool without requiring delivery of the higher actuation pressure along the entire wellbore. An actuation module may be used in combination with the power generation module to control operation of the power generation module in response to command signals sent downhole.