Reactive Material Actuator for Downhole Well Tool

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Solution Overview

Problem

Conventional methods for actuating downhole well tools face limitations such as temperature constraints and operational safety issues, necessitating improvements in power supply and actuation mechanisms.

Innovation Solution

The use of reactive materials to release chemical energy, which is then utilized for thermal expansion to apply pressure to a piston, thereby actuating well tools, allowing for multiple actuations without the need for explosives or high-pressure containers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional power sources (batteries, compressed gas) are used to actuate well tools, then the tools can be operated, but temperature limitations and operational safety issues arise

Engineering Contradiction:

Improveoperational safetyVSAvoidtemperature limitations

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent replaces conventional mechanical power sources (batteries, compressed gas containers) with a chemical reaction-based actuation system. Reactive materials undergo exothermic reactions that directly generate thermal energy to expand a substance and drive the piston, eliminating the need for traditional mechanical power supply components and their associated temperature and safety limitations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the physical state of a substance (solid/liquid to gas) through thermal expansion caused by chemical reaction heat. This phase change and expansion provides the necessary pressure to actuate the well tool, converting chemical energy directly into mechanical work without requiring conventional power sources that are constrained by temperature and safety issues.

Inventive Principle:

Principle #35Parameter changes

2Duration of action of moving object

If reactive materials are used to generate thermal expansion, then multiple actuations are enabled, but the system complexity increases

Engineering Contradiction:

Improvemultiple actuationsVSAvoidsystem complexity

Core Design Contradiction:

Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The reactive material system is divided into multiple separate portions or cartridges, each capable of independent activation. This segmentation allows for multiple discrete actuations of the well tool, as each portion can be activated sequentially to provide repeated mechanical impulses without requiring a continuously complex power management system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs disposable reactive material portions that are consumed during each actuation cycle. These simple, replaceable components provide a cost-effective and straightforward method to achieve multiple actuations, avoiding the need for complex rechargeable or regenerative systems while maintaining operational flexibility.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 method provides a reliable and efficient means of actuating well tools, enabling multiple operations while maintaining safety and avoiding temperature-related limitations, with the ability to remotely control and reuse the actuation system.

Implementation Method 1

releasing chemical energy from at least one portion of a reactive material

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 2

thermally expanding a substance in response to the released chemical energy

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

applying pressure to a piston as a result of thermally expanding the substance

Methodology Applied

Scientific EffectPressure generation through thermal expansion: Thermal Expansion

Data Source

PatentUS9822609B2Well tools operable via thermal expansion resulting from reactive materials

Publication Date: 2017.11.21 HALLIBURTON ENERGY SERVICES INC

AI summary

Methods of actuating a well tool can include releasing chemical energy from at least one portion of a reactive material, thermally expanding a substance in response to the released chemical energy, and applying pressure to a piston as a result of thermally expanding the substance, thereby actuating the well tool, with these steps being repeated for each of multiple actuations of the well tool. A well tool actuator can include a substance contained in a chamber, one or more portions of a reactive material from which chemical energy is released, and a piston to which pressure is applied due to thermal expansion of the substance in response to each release of chemical energy. A well tool actuator which can be actuated multiple times may include multiple portions of a gas generating reactive material, and a piston to which pressure is applied due to generation of the gas.