Setting Tool Adaptor With Thermal Fuse for False Signal Isolation
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Solution Overview
Problem
Existing setting tools in wellbore completion operations experience false electrical signals due to surviving circuitry post-ignition, leading to inaccurate detection of plug actuation and charge status.
Innovation Solution
A setting tool adaptor with an ignitor and electrically grounded thermal fuse is used to initiate combustion, ejecting the ignitor into a logic cavity and activating the thermal fuse to render the internal circuitry unreadable, while isolating hot gases from upstream tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the setting tool circuitry is left intact after ignition, then the setting tool can be reused, but false electrical signals are generated leading to inaccurate detection
Solution Approach 1:
The ignitor is extracted as a separate component that can be ejected from the setting tool body during ignition. This allows the ignitor to be removed while leaving the circuitry intact for potential reuse, resolving the contradiction between signal accuracy and circuitry preservation
Solution Approach 2:
A thermal fuse acts as an intermediary component between the ignitor and the circuitry. The thermal fuse melts during ignition to sever the electrical connection, preventing false signals while allowing the circuitry to remain physically intact for future operations
2Object-affected harmful factors
If the ignitor remains in the setting tool after combustion, then the structure is simple, but hot gases can damage upstream tools
Solution Approach 1:
The setting tool is segmented into distinct functional zones: an ignitor cavity for combustion, a logic cavity for electronics, and a tandem for upstream tool isolation. This segmentation contains hot gases within specific boundaries while maintaining overall structural simplicity
Solution Approach 2:
The tandem serves as an intermediary barrier between the combustion zone and upstream tools. It isolates hot gases and combustion byproducts from the perforating gun and other upstream equipment, preventing damage while requiring minimal structural modification
3Reliability
If the thermal fuse is not electrically grounded, then the circuitry remains functional, but false signals continue to be transmitted
Solution Approach 1:
The thermal fuse is merged with the grounding system by electrically connecting it to a ground wire. This combination ensures that when the thermal fuse melts during ignition, it simultaneously severs the electrical signal path and establishes a ground connection, reliably terminating false signals with minimal manufacturing complexity
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
Ensures that the setting tool circuitry is severed, preventing false electrical signals and improving the accuracy of plug actuation detection during wellbore completion operations.
Implementation Method 1
the ignitor initiates a combustion of the power charge. Pressure and heat generated by the combustion of the power charge ejects the ignitor into the logic cavity
Implementation Method 2
Pressure and heat generated by the combustion of the power charge ejects the ignitor into the logic cavity and initiates the thermal fuse to render internal circuitry unreadable
Data Source
AI summary
A setting tool adaptor for attachment to a tandem and a setting tool is provided. The setting tool adaptor includes an ignitor within an ignitor cavity and includes an electrically grounded thermal fuse within a logic cavity. The ignitor is adjacent a power charge in a setting tool, such that the ignitor initiates a combustion of the power charge. Pressure and heat generated by the combustion of the power charge ejects the ignitor into the logic cavity and initiates the thermal fuse to render internal circuitry unreadable, while the adjacent tandem isolates the hot gases from an upstream perforating gun or other upstream tool.