Inverted Igniter Power Charge for Controlled Wellbore Actuation
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Solution Overview
Problem
Current power charges used in wellbore tools often produce excessive and unpredictable forces due to uncontrolled chemical reactions, which can damage tools and wellbores, and fail to achieve desired slow-set actuations effectively.
Innovation Solution
A power charge design with an integrated igniter and a booster charge, where the igniter is positioned to initiate combustion closer to the gas diverter channel, allowing unimpeded gas pressure to actuate the tool, and a booster holder ring to enhance deflagration, reducing uncombusted material obstruction and enabling controlled force delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the igniter is positioned at the distal end of the power charge (conventional design), then the chemical reaction proceeds toward the piston, but the unreacted power charge blocks the expanding gas from exerting force on the piston, causing excessive initial force and unpredictable actuation
Solution Approach 1:
The igniter is inverted from its conventional position at the distal end to the proximal end of the power charge. This inversion changes the direction of the chemical reaction propagation, allowing expanding gases to escape axially through the distal end without being blocked by unreacted power charge, thereby eliminating excessive initial forces and enabling reliable slow-set actuation.
Solution Approach 2:
The igniter is positioned to initiate combustion at the proximal end before the chemical reaction progresses through the power charge. This preliminary positioning ensures that the reaction front moves away from the piston side, allowing gas pressure to build and actuate the tool smoothly without obstruction from unreacted material.
2Duration of action of moving object
If a strong force is delivered over a short time duration, then the tool may be actuated, but the actuation is not ideal and cannot achieve desired slow-set options
Solution Approach 1:
The system transitions from a static force delivery mode (strong force over short duration) to a dynamic mode where force is delivered gradually over an extended period. The inverted igniter configuration allows the chemical reaction to progress while simultaneously enabling gas expansion and tool actuation, creating a dynamic slow-set process that lasts several seconds rather than milliseconds.
3Duration of action of moving object
If the power charge is configured to provide force over several seconds (slow-set), then desired actuation is achieved, but unreacted power charge obstructs the expanding gas path
Solution Approach 1:
By inverting the igniter position, the chemical reaction propagates from the proximal end toward the distal end, creating a clear axial escape path for expanding gases. This eliminates the obstruction problem that would otherwise prevent smooth slow-set operation, as unreacted power charge no longer blocks the gas flow path.
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
This design reduces extraneous forces, allows for more predictable and controlled actuation, and enables efficient slow-set options by ensuring that expanding gases can actuate the tool without obstruction, minimizing the risk of damage and improving operational reliability.
Implementation Method 1
activation of the chemical reaction in the power charge results in a substantial force being exerted on the setting tool piston
Implementation Method 2
The force exerted to set a plug is typically exerted on a piston in the setting tool, with the piston acting to deform or displace portions of the plug
Data Source
AI summary
A power charge for actuating a wellbore tool. Combustion of the power charge generates gas and corresponding gas pressure within the wellbore tool and the power charge and wellbore tool are configured for providing a path to an expansion chamber for the gas pressure. A body of the power charge may have the shape of a regular polygonal cylinder, thus defining flow-paths for the expanding gas. The power charge may include a cylinder of energetic material and an interior space formed within the energetic material and configured for receiving an igniter and/or ignition material. Ignition of the igniter or ignition material results in combustion of the power charge.