Single-Use Wellbore Setting Tool with Integrated Gas Charge
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Solution Overview
Problem
Current wellbore setting tools are complex, expensive, and require skilled operators for resetting, with a high risk of human error during assembly and maintenance, due to their complex nature and the need for precise engineering tolerances.
Innovation Solution
A single-use setting tool design that includes a piston and sleeve configuration with a built-in initiator holder and gas-generating power charge, eliminating the need for a separate firing head and allowing for safe, predictable, and economical operation with fewer, simpler parts that can be made from less expensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a complex reusable setting tool is used, then the tool can be reset and reused multiple times, but the complexity of assembly and maintenance increases, requiring skilled operators and precise engineering tolerances
Solution Approach 1:
The patent applies the disposable principle by designing a setting tool with a firing head that is intended for single use only. The firing head contains a power charge that is consumed during operation, making the entire firing head assembly disposable rather than reusable. This eliminates the need for complex resetting procedures and skilled operator intervention for maintenance, directly resolving the contradiction between tool reusability and assembly complexity.
Solution Approach 2:
The patent merges the firing head with the power charge into a single integrated assembly. By combining these components that were previously separate and required complex assembly procedures, the design simplifies the overall structure. The merged firing head assembly can be easily replaced as a single unit, reducing assembly complexity while maintaining tool functionality.
2Ease of manufacture
If a reusable setting tool is used, then cost can be reduced through multiple uses, but the risk of human error during assembly and maintenance increases
Solution Approach 1:
By making the firing head disposable, the patent eliminates human error risks associated with resetting and maintenance operations. Although each firing head is single-use, the elimination of skilled operator intervention and potential errors during complex assembly and maintenance procedures improves overall reliability. The simplified replacement process reduces error risk compared to reusable tool maintenance.
3Adaptability or versatility
If a setting tool with separate firing head is used, then functionality can be maintained, but the number of parts increases and cost increases
Solution Approach 1:
The patent merges the firing head and power charge into a single integrated assembly, reducing the number of separate parts. This merged design maintains all necessary functionality while simplifying the overall tool structure. The reduced part count lowers manufacturing cost and simplifies assembly procedures, directly addressing the contradiction between functionality and device complexity.
4Reliability
If precise engineering tolerances are maintained in reusable tools, then reliability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
By making the firing head disposable, the patent can use less expensive manufacturing methods with relaxed tolerances for the disposable component itself. The reliability of the setting operation is maintained through the precision of the main tool body, while the disposable firing head does not require the same level of precision, thereby reducing manufacturing cost and 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
The single-use setting tool reduces the complexity and cost of wellbore operations, minimizes the need for skilled labor and maintenance, and enhances safety by simplifying the assembly and operation process while maintaining the reliability and effectiveness of current tools.
Implementation Method 1
combustion of the power charge may generate gas pressure to urge the piston against a setting sleeve
Implementation Method 2
activation of the power charge results in a substantial force by means of combustion being exerted on the setting tool piston
Data Source
AI summary
A single use setting tool and associated method for actuating a tool in a wellbore may include an inner piston having a piston proximal end, a piston distal end, and a piston annular wall that defines a piston cavity. The setting tool may include a gas-generating power charge positioned within the piston cavity. The power charge may extend along a longitudinal axis from a proximal end to a distal end and have at least two different widths along its length. The power charge may further include a tapered portion. The setting tool may further include a piston extension connected to the piston distal end. The inner piston may further include a shear element groove circumferentially extending in an outer surface of the inner piston, for receiving a shear element.