Wellbore Tool Control Module for Pyrotechnic-Free Sequential Initiation
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Solution Overview
Problem
Conventional pyrotechnic time delay devices used in wellbore perforation systems are unreliable due to temperature-dependent deflagration reactions, require user expertise, and pose safety hazards, necessitating a pyrotechnic-free initiation method for wellbore tool strings.
Innovation Solution
A control module with a pressure-actuated safety switch and logic circuit that autonomously initiates wellbore tools based on pressure and environmental conditions, eliminating the need for pyrotechnic time delay fuses by using mechanical and electronic pressure sensors and microcontrollers to ensure safe and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pyrotechnic time delay devices are used to initiate wellbore tools, then time delay function is achieved, but safety hazards increase and reliability decreases due to temperature-dependent deflagration reactions
Solution Approach 1:
The patent removes pyrotechnic components from the wellbore tool string by extracting the time delay function into a separate surface-based computer system. The downhole initiation system uses only electronic sensors and actuators, eliminating combustible and explosive materials from the downhole environment while maintaining the time delay capability through surface computation and signal transmission.
Solution Approach 2:
The patent replaces the chemical deflagration-based pyrotechnic time delay system with an electronic control system using pressure sensors, temperature sensors, microcontrollers, and electronic signal transmission. This substitution eliminates the temperature-dependent chemical reactions and replaces them with electronic measurement and control mechanisms that are not susceptible to the same safety hazards.
2Ease of operation
If pyrotechnic time delay devices are used, then time delay is achieved, but user expertise requirements increase and on-site assembly becomes necessary
Solution Approach 1:
The patent implements self-service through automated electronic systems that perform sensing, computation, and initiation control without requiring user intervention. The microcontrollers automatically process sensor data, calculate time delays based on environmental conditions, and trigger initiation sequences without user input. The system configures itself based on pre-programmed logic, eliminating the need for users to consult time-temperature charts or perform complex assembly procedures.
Solution Approach 2:
The patent creates a universal initiation system that can handle multiple functions through a single integrated electronic control platform. The surface computer can manage time delay calculations, environmental monitoring, safety interlocks, and initiation sequencing for various wellbore tools using different actuation mechanisms (pyro actuators, hydraulic actuators, electric motors). This multi-functional approach replaces multiple specialized pyrotechnic components with one adaptable electronic system.
3Ease of manufacture
If pyrotechnic components are used in wellbore tools, then initiation capability is achieved, but manufacturing and shipping complexity increase
Solution Approach 1:
The patent extracts all pyrotechnic components from the downhole tool string and relocates them to the surface facility. This allows the downhole tools to be manufactured and shipped without sensitive explosive materials, simplifying manufacturing processes and shipping requirements. The pyrotechnic initiators remain at the surface where they can be stored and handled under controlled conditions, while the downhole tools use only non-sensitive electronic and mechanical components.
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 provides reliable and safe initiation of wellbore tools without pyrotechnic components, improving safety, reliability, and efficiency by ensuring tools are only activated under precise pressure and environmental conditions, reducing on-site assembly requirements and costs.
Implementation Method 1
A control module with a pressure-actuated safety switch and logic circuit that autonomously initiates wellbore tools based on pressure and environmental conditions
Implementation Method 2
using mechanical and electronic pressure sensors and microcontrollers to ensure safe and reliable operation
Data Source
Figure 1
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AI summary
A control module for use with a plurality of wellbore tools may include a power source and a logic circuit operably coupled to the power source. The logic circuit may be operably coupled to the plurality of wellbore tools through a topmost wellbore tool of the plurality of wellbore tools. The logic circuit may be configured to, in response to an initiation condition and for each wellbore tool of the plurality of wellbore tools in a sequential order from a bottommost wellbore tool to the topmost wellbore tool, determine whether the wellbore tool is a responsive wellbore tool or a non-responsive wellbore tool. In response to a determination that the wellbore tool is a responsive wellbore tool, the logic circuit may initiate the wellbore tool. In response to a determination that the wellbore tool is a non-responsive wellbore tool, the logic circuit may skip initiation of the wellbore tool.