Wireline Pressure Setting Tool Hydraulic Conversion
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Solution Overview
Problem
The use of explosive setting tools in wellbore operations poses safety hazards, requires specialized personnel, and involves complex maintenance due to the need for controlled handling and storage of explosives, as well as the risk of hazardous chemical exposure during depressurization.
Innovation Solution
A non-explosive setting tool is developed by retrofitting explosive setting tools with a conversion assembly that includes a motor controller, gear motor, and hydraulic pump, replacing explosive elements with insulated contact terminals and a hydraulic pump, and adding a face seal mechanism to manage hydraulic fluid pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If explosive setting tools are used to set auxiliary tools in wellbore operations, then the setting function can be achieved, but safety hazards and the need for specialized personnel increase
Solution Approach 1:
The patent replaces the explosive (chemical) system with a hydraulic system. The setting tool uses a hydraulic motor driven by pressurized fluid to rotate a setting mandrel, which then engages the auxiliary tool. This mechanical substitution eliminates the use of explosives while achieving the same setting function, thereby removing safety hazards associated with explosive handling and storage.
Solution Approach 2:
The patent employs a hydraulic system where pressurized fluid is pumped through a conduit to a hydraulic motor in the setting tool. The hydraulic motor converts fluid pressure into rotational motion to drive the setting mechanism. This pneumatic/hydraulic approach provides a safe, controlled alternative to explosive activation while maintaining the ability to set auxiliary tools at desired depths.
2Reliability
If explosive setting tools are used, then the setting function can be achieved, but specialized personnel and complex maintenance are required
Solution Approach 1:
By replacing the explosive system with a hydraulic system, the patent eliminates the need for specialized explosives personnel. The hydraulic system uses standard industrial components (pump, conduit, hydraulic motor) that are more familiar to general maintenance personnel, thereby reducing maintenance complexity and training requirements.
3Reliability
If explosive setting tools are used, then the setting function can be achieved, but the risk of hazardous chemical exposure during depressurization increases
Solution Approach 1:
The patent substitutes the chemical explosive system with a mechanical hydraulic system. The hydraulic fluid used is non-hazardous and can be safely handled and disposed of. During depressurization, the hydraulic system simply releases fluid pressure without generating hazardous chemicals, thereby eliminating the exposure risk associated with explosive byproducts.
4Object-affected harmful factors
If a non-explosive hydraulic system is used, then safety hazards are eliminated, but the system complexity increases due to additional components
Solution Approach 1:
The hydraulic system components (pump, conduit, hydraulic motor) are standard multi-functional components used across various industrial applications. This universality allows the system to be designed and maintained using existing knowledge and parts, offsetting the apparent increase in complexity by leveraging proven, standardized components rather than custom-made parts.
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
This solution eliminates the risks associated with explosive tools, simplifies maintenance, and reduces the need for specialized personnel by using a safe and controlled hydraulic system for setting and resetting tools, enhancing operational safety and efficiency.
Implementation Method 1
a hydraulic pump, and a face seal. The hydraulic pump is in fluid communication with the piston
Implementation Method 2
adding a face seal mechanism to manage hydraulic fluid pressure
Data Source
AI summary
A method and apparatus for retro-fitting an explosive setting tool to a non-explosive setting tool is provided to eliminate the use of pyrotechnics when setting auxuliary tools. An explosive setting tool is retro-fitted by removing the pyrotechnic elements of the tool and replacing them with a conversion assembly including a hydraulic pump, thus converting the explosive tool into a non-explosive tool. The hydraulic pump provides the energy necessary to set the auxiliary tool. Once the auxiliary tool has been set, the non-explosive setting tool can be brought to the surface and reset using a resetting tool.