Multi-Stage Downhole Setting Tool with Controlled Force-Time Profile
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Solution Overview
Problem
Existing downhole setting tools face challenges such as high costs, limited high-temperature operation, and rapid force-time profiles that can damage components, along with regulatory complexities for pyrotechnic tools and inefficiencies in hydrostatic pressure utilization.
Innovation Solution
A multi-stage setting tool utilizing hydrostatic pressure with electronically ruptureable discs to control fluid flow into piston chambers, allowing for customizable force-time profiles and operation at high temperatures, with modular design and controlled fluid ingress to manage pressure and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydrostatic pressure is applied very quickly to provide setting force, then productivity is improved, but the components move at rapid speeds which can damage sealing elements and break metallic components
Solution Approach 1:
The single-stage rapid setting process is divided into multiple stages with controlled pressure application. The system uses a multi-chamber piston arrangement where each chamber fills sequentially, transforming one rapid high-force application into several controlled stages, thereby maintaining productivity while reducing peak speeds that cause component damage
Solution Approach 2:
The system dynamically controls fluid flow rates into each piston chamber using flow restrictors and electronically ruptureable discs. The flow rate is adjusted to optimize the force-time profile, allowing rapid setting when needed while preventing excessive speeds that would damage components, thus adapting the setting speed to operational requirements
2Force
If pyrotechnic material is used to generate pressure for setting, then force generation capability is improved, but extensive and costly regulations including special shipping, handling, storage, and inspections are required
Solution Approach 1:
The patent replaces pyrotechnic (chemical) pressure generation with a hydrostatic hydraulic system. Wellbore hydrostatic pressure drives fluid into piston chambers to generate setting force, eliminating the need for pyrotechnic materials and their associated regulatory complexities while maintaining the required force generation capability
Solution Approach 2:
The system uses hydraulic fluid pressurized by wellbore hydrostatic pressure to generate setting force. Fluid is directed into piston chambers through controlled ports, creating mechanical force through hydraulic pressure rather than chemical explosion, thereby avoiding pyrotechnic regulations while achieving the necessary setting force
3Power
If a large stack of batteries is used to drive the motor for setting, then power output capability is improved, but the maximum operating temperature is limited and transportation cost increases
Solution Approach 1:
The patent replaces the battery-powered electric motor system with a hydrostatic hydraulic system. Wellbore hydrostatic pressure directly drives the hydraulic pistons, eliminating batteries and their temperature constraints. This allows operation in high-temperature environments without limiting power output capability
Solution Approach 2:
The system utilizes the wellbore's own hydrostatic pressure as the power source, eliminating the need for external battery packs. The formation pressure itself provides the energy needed to drive the setting tool, removing transportation and temperature limitations associated with battery storage while maintaining sufficient power output
4Device complexity
If a single-stage setting tool is used, then device complexity is reduced, but the force-time profile is either too quick causing damage or requires excessive stroke distance
Solution Approach 1:
The setting tool is divided into multiple stages with separate piston chambers that activate sequentially. Each stage contributes to the overall setting force while controlling the force-time profile, preventing the excessive speed and component damage associated with single-stage tools, while the modular design keeps complexity manageable
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 provides a cost-effective, high-force setting capability over a long stroke with customizable force-time profiles, avoiding regulatory issues of pyrotechnic tools and reducing component damage, while enabling operation in high-temperature environments.
Implementation Method 1
Hydrostatic setting tools convert ambient hydrostatic pressure in a wellbore into hydraulic force to set the downhole tool
Implementation Method 2
A first port is opened to a first piston chamber having a first piston mounted therein for sliding movement. A fluid at hydrostatic pressure, flows into the first pressure chamber through the first port
Data Source
AI summary
A multi-stage setting tool actuated by hydrostatic pressure downhole is provided with a selectable force-time profile during setting. A first port opens a first piston chamber to hydrostatic pressure which drives a first piston. A force-transmitting member, attached to the piston, is driven in response to the fluid pressure increase in the chamber. The process is repeated with sequential ports and piston chambers. A settable tool is set in response to the driving of the force-transmitting member by the pistons. The combined stroke distances and forces of the pistons are selected to set the tool. Opening of the ports can occur in response to electrical signal and can be conditional on occurrence of a selected event or condition. Speed of setting can be regulated.