Downhole Setting Tool Wrench Application Protection
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Solution Overview
Problem
Conventional downhole setting tools for frac plugs, bridge plugs, and packers often suffer from premature failure of shear devices during attachment to firing heads, leading to increased expenses and delays due to damage caused by improper torque application.
Innovation Solution
A gas-operated setting tool design featuring a mandrel with an extended wrench-application portion that protects the shear device by allowing torque application away from the shear device, coupled with a barrel piston and interior combustion chamber for reliable deployment of plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the shear device is positioned close to the attachment point for compact design, then the device complexity is reduced, but the shear device is vulnerable to damage during torque application
Solution Approach 1:
A protective extension or guard structure is introduced as an intermediary element between the torque application point and the shear device. This mediator shields the shear device from direct torque forces during attachment operations, preventing damage while maintaining the compact overall structure.
Solution Approach 2:
The attachment structure is segmented into distinct functional zones: a torque application region, a protective transition zone, and a shear device mounting region. This segmentation allows the torque to be applied at a safe distance from the shear device while maintaining structural integrity through the divided design.
2Reliability
If the wrench application point is positioned far from the shear device to protect it, then the reliability improves, but the device length increases
Solution Approach 1:
The protective extension is designed to nest within or alongside existing mandrel structures, utilizing the available radial or axial space efficiently. This nested arrangement provides the necessary protection distance without significantly increasing the overall device length.
Solution Approach 2:
Instead of extending the protective feature only in the axial direction (increasing length), the design utilizes radial or circumferential dimensions to provide protection. The protective extension may protrude radially or wrap around the shear device, achieving protection through dimensional redirection rather than simple length extension.
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 enhances the reliability and consistency of setting tool handling, reducing the risk of shear device damage and enabling more efficient plug deployment, thereby minimizing delays and expenses.
Implementation Method 1
The mandrel is formed with an interior combustion chamber
Data Source
AI summary
A setting tool for use in wells includes a mandrel formed with an interior combustion chamber. The setting tool further includes a barrel piston sized and configured to extend at least partially over an exterior of the mandrel and a shear device coupled to a portion of the mandrel and coupled to the barrel piston when in an in-line configuration. The mandrel includes an upper portion having a lead portion, an engagement portion, and a wrench-application portion. The wrench-application portion has a longitudinal length in the range of 1.5 to 3.0 to receive a wrench and avoid damage to the shear device. Other tools are disclosed.