Single-Use Wellbore Setting Tool with Integrated Power 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 potential damage from excessive force or shock.
Innovation Solution
A single-use setting tool design featuring a simpler structure with fewer parts, made from less expensive materials with less stringent tolerances, which includes an outer sleeve and inner piston configured for axially sliding relative to each other, and a power charge integral with the tool for controlled actuation without the need for a separate firing head.
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 device complexity, manufacturing cost, and operational risk increase
Solution Approach 1:
The patent applies the disposable principle by designing a setting tool with a consumable power charge that is discarded after a single use. This eliminates the complexity of making the entire tool reusable while maintaining productivity through standardized replacement of the power charge component.
2Ease of operation
If a separate firing head is used to initiate the power charge, then the actuation can be controlled, but the device complexity and number of parts increase
Solution Approach 1:
The patent merges the power charge with the setting tool body into a single integrated unit. The power charge is positioned within the tool housing and directly coupled to the actuation mechanism, eliminating the need for a separate firing head while maintaining controlled actuation through the integrated design.
3Speed
If high force is applied by the power charge to actuate the tool quickly, then the actuation speed increases, but the risk of damage to the setting tool, other downhole tools, or the wellbore increases
Solution Approach 1:
The patent incorporates a shock-absorbing element positioned between the power charge and the actuation mechanism. This cushioning element is designed to absorb excess force generated during power charge actuation, protecting the setting tool and other downhole tools from damage while maintaining adequate actuation speed.
4Speed
If the power charge generates force over a very short time duration, then the actuation is fast, but the setting characteristics may not be ideal for certain tools
Solution Approach 1:
The patent designs the power charge with variable force delivery characteristics, allowing the force application rate to change during actuation. The power charge is configured to deliver high initial force for rapid actuation followed by a controlled decay phase that provides extended force application, enabling both fast actuation and reliable setting characteristics.
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 provides a safe, predictable, and economical solution for wellbore operations, reducing the risk of human error and operational costs by eliminating the need for skilled resetting and complex component management.
Implementation Method 1
combustion of the power charge may generate gas pressure to urge the piston
Implementation Method 2
The shear pins will shear under a threshold amount of force
Data Source
AI summary
A single use setting tool for actuating a tool in a wellbore may include an outer sleeve and an inner piston received within a central bore of the outer sleeve. The inner piston may define one or more elongate bores therethrough that are in fluid communication with a cavity of the inner piston and extend axially through a distal end portion of the inner piston. The distal end portion of the inner piston may abut a shoulder of the outer sleeve, for example at a distal end face of the inner piston.