Gas-Operated Setting Tool Shear Ring Mechanism
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Solution Overview
Problem
Existing setting tools for zone isolation in oil or gas wells are limited by their design, which restricts the use of disposable securing mechanisms and suitable materials, leading to high costs and production times, and require careful handling to avoid inadvertent shearing during deployment.
Innovation Solution
A gas-operated setting tool design featuring a cylinder, piston rod, and top cap with a shear ring mechanism that prevents axial movement until a power charge is fired, allowing for a disposable and cost-effective solution with components made from tubing, including a modular piston rod and a 'Go Style' power charge chamber for efficient gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shear screw is used to retain the setting tool in the unstroked configuration, then the tool can be secured during hook-up and run-in, but rotational forces may cause inadvertent shearing of the shear screw
Solution Approach 1:
The patent replaces the traditional shear screw mechanical securing mechanism with a shear ring that engages between the piston rod and top cap. This substitution eliminates the vulnerability to rotational forces that caused inadvertent shearing of shear screws, while maintaining the function of securing the tool in the unstroked configuration during hook-up and run-in operations.
2Reliability
If specially machined components are used in the setting tool, then the tool can function properly, but the cost and production time increase significantly
Solution Approach 1:
The patent adopts a disposable setting tool design where components such as the piston rod, top cap, and cylinder can be manufactured from readily available tubing materials rather than requiring expensive specially machined components. The tool is designed to be used once and then discarded, eliminating the need for complex machining and reducing both production cost and time while maintaining adequate functionality for single-use applications.
Solution Approach 2:
The setting tool is divided into separate modular components (piston rod, top cap, cylinder, bottom connector) that can be independently manufactured from standard tubing and assembled. This segmentation allows each component to be produced using simple processes and enables easy replacement or disposal of individual parts, reducing overall manufacturing complexity and cost.
3Productivity
If the power charge chamber is designed with direct gas flow paths, then the gas flow efficiency is improved, but the chamber design becomes more complex
Solution Approach 1:
The patent extracts the gas flow paths as separate port holes directly through the piston rod, rather than incorporating complex internal flow channels within the power charge chamber. This extraction of the flow path function to simple ports maintains gas flow efficiency by providing direct pathways from the power charge chamber to the actuation points, while avoiding the complexity of designing and manufacturing intricate internal flow passages.
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
Enables secure and efficient deployment of zone isolation devices with reduced material costs and production time, allowing for the use of tubing components and ensuring the tool is disposable after a single run, while maintaining safety and operational efficiency.
Implementation Method 1
The power charge chamber is configured to receive a power charge and has gas ports that extend from the power charge chamber directly onto the bottom connector. When the power charge is fired, it generates high-pressure gas that acts on the bottom connector to stroke the setting tool.
Implementation Method 2
A shear ring between the top cap and piston rod prevents axial movement of the setting tool until the power charge has fired and sheared the shear ring to stroke the setting tool.
Data Source
AI summary
A gas operated setting tool comprising a piston rod and an outer tool assembly having a hollow interior within which the piston rod is disposed coaxially. The outer tool assembly comprises a top cap connected to the cylinder's upper end and a bottom connector connected to the cylinder's lower end. The piston rod comprises an upper section to which a firing head attaches and a lower section to which a setting adapter attaches. The piston section's exterior surface fits within and is sealed against the cylinder's interior surface. The piston rod has a hollow power charge chamber and port holes that open into the bottom connector's upper surface. A shear ring engages a counterpart surface feature to prevents axial movement of the outer tool assembly relative to the piston rod until the power charge has fired and sheared the shear ring.