Downhole Plug Setting Tool Hydraulic Actuation
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Solution Overview
Problem
In wellbore completion processes, existing tools face challenges in effectively setting and sealing downhole plugs within casing strings to isolate specific sections for hydraulic fracturing, as current methods lack efficient mechanisms for actuating plugs and ensuring reliable fluid isolation.
Innovation Solution
A setting tool comprising a housing with a mandrel and piston configuration, where pressurization of the central passage displaces the mandrel between positions, creating fluid communication pathways and using a pressure charge to actuate the plug for sealing against the tubular string, coupled with a firing head and wireline for ignition, enables precise plug setting and fluid isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a downhole plug is used to isolate wellbore sections, then fluid isolation is achieved, but reliable actuation and sealing mechanisms are difficult to implement
Solution Approach 1:
The setting tool uses hydraulic principles by utilizing the formation fluid pressure itself to actuate the plug. The piston is exposed to formation pressure on one side and plug setting force on the other side, creating a self-actuating mechanism that eliminates complex mechanical actuators and improves reliability.
Solution Approach 2:
The system uses the formation fluid pressure to automatically actuate the plug for sealing. The pressure differential created by the formation fluid itself provides the force needed to move the piston and set the plug, making the system self-actuating without requiring external power sources or complex control mechanisms.
2Reliability
If existing plug setting tools are used, then some sealing capability is achieved, but efficient fluid communication and isolation are not reliably ensured
Solution Approach 1:
The system incorporates feedback through the piston position sensing mechanism that monitors the actuation state. The pressure differential across the piston provides continuous feedback on the sealing status, allowing the system to confirm when the plug is properly set and maintain reliable fluid isolation.
Solution Approach 2:
The tool efficiently manages fluid communication by using hydraulic pressure differentials to control the plug position. The formation fluid pressure directly drives the actuation process, ensuring efficient and reliable sealing without requiring complex mechanical transmission systems.
3Reliability
If a complex setting tool mechanism is used to actuate the plug, then sealing capability improves, but device complexity increases
Solution Approach 1:
The invention extracts and eliminates complex mechanical actuation mechanisms from the setting tool. By removing the need for external actuators, motors, or complex transmission systems, the design achieves sealing capability through a simple piston exposed to formation pressure, significantly reducing device complexity.
Solution Approach 2:
The setting tool replaces complex mechanical structures with a simple hydraulic principle. The piston utilizes formation fluid pressure to generate the necessary force for plug sealing, eliminating the need for motors, gears, or other complex mechanical components while maintaining reliable sealing capability.
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 enables reliable sealing and isolation of wellbore sections, facilitating effective hydraulic fracturing by ensuring proper plug actuation and fluid communication, enhancing the efficiency of the plug-n-perf operation.
Implementation Method 1
a pressure charge disposed in the setting tool, wherein the firing head is configured to ignite the pressure charge in response to receiving a signal transmitted by the wireline
Implementation Method 2
fluid communication between the first chamber and the second chamber is restricted when the mandrel is in the first position, and wherein fluid communication is permitted between the first chamber and the second chamber when the mandrel is in the second position
Implementation Method 3
an annular seal positioned between the mandrel and the housing, wherein the annular seal forms a first chamber and a second chamber in the housing
Implementation Method 4
in response to a pressurization of the central passage of the piston of the setting tool, the setting tool is configured to actuate the plug to seal against the inner surface of the tubular string
Data Source
AI summary
A tool string disposable in a wellbore includes a plug configured to seal against an inner surface of a tubular string disposed in the wellbore, a setting tool coupled to the plug, including a housing including a central passage, a mandrel slidably disposed in the housing, wherein the mandrel includes an outer surface including a planar surface, and a piston coupled to the mandrel and including a central passage, wherein, in response to a pressurization of the central passage of the piston of the setting tool, the setting tool is configured to actuate the plug to seal against the inner surface of the tubular string.